CONTENTS BREAK-IN .........................................................................................2-1 Breaking in New Machine.............................................................2-1 Securing Machine to Trailer for Transportation....................6-3 Unloading...........................................................................................6-4 Lifting Machine with Crane..........................................................6-5 OPERATING ENGINE ...................................................................3-1 Before Starting Engine...................................................................3-1 Starting Engine.................................................................................3-2 Check Machine After Starting Engine......................................3-5 Using Booster Battery.....................................................................3-6 Stopping Engine..............................................................................3-7 MAINTENANCE ..............................................................................7-1 Procedures..........................................................................................7-1 Prepare Machine for Inspection/Maintenance.....................7-2 Opening/Closing Engine Access Covers..................................7-3 Opening/Closing Tank Covers (ZX27-3)...................................7-4 Opening/Closing Right Side Covers (ZX27-3)........................7-5 Daily Inspection................................................................................7-6 Periodic Replacement of Parts....................................................7-8 Maintenance Guide.........................................................................7-9 Brand Names of Recommended DRIVING MACHINE ......................................................................4-1 Travel Levers .....................................................................................4-1 Travel Mode Switch (ZX16-3, 18-3, 27-3).................................4-3 Traveling on Soft Ground..............................................................4-4 Raise One Track Using Boom and Arm.....................................4-4 Towing Machine...............................................................................4-5 Driving in Water or on Soft Ground...........................................4-6 Parking and Stopping on Slopes................................................4-7 Parking on Slopes............................................................................4-7 Oil and Lubricants...................................................................7-12 A.
Greasing......................................................................................7-15 Front Joint Pins (Incl. Swing Post Joint Pins)..................7-15 Bucket and Link Pins..............................................................7-18 Blade Pins (ZX27-3).................................................................7-18 Swing Bearing ..........................................................................7-19 Swing Internal Gear ...............................................................7-20 Control Lever Universal Joint..............................................7-20 B.
Engine..........................................................................................7-21 OPERATING MACHINE ...............................................................5-1 Control Lever (ISO Excavator Pattern)......................................5-1 Boom-Swing Pedal..........................................................................5-2 Auxiliary Pedal..................................................................................5-3 Blade Lever.........................................................................................5-4 Precautions for Blade Operation................................................5-5 Blade and Track Width Engine Oil ..................................................................................7-21 Change Engine Oil / Replace Engine Oil Filter .............7-22 C.
Transmission..............................................................................7-24 Control Lever Operation (ZX18-3)........................................5-6 Extending / Retracting Blade Width Travel Reduction Gear...........................................................7-24 D.
Hydraulic System.....................................................................7-27 (ZX18-3).........................................................................................5-7 Pilot Control Shut-Off Lever.........................................................5-8 Warming Up Operation..............................................................5-10 Warming Up in Cold Weather...................................................5-10 Operating Backhoe......................................................................5-11 Grading Operation.......................................................................5-12 Avoid Driving Bucket Teeth into Ground.............................5-12 Avoid Abusive Operation...........................................................5-12 Avoid Striking with Bucket........................................................5-13 Avoid Excavation Using Upperstructure and/or Check Hydraulic Oil Level ....................................................7-28 Drain Hydraulic Oil Tank Sump...........................................7-29 Change Hydraulic Oil ............................................................7-30 Clean Suction Filter.................................................................7-33 Replace Full Flow Filter .........................................................7-34 Replace Pilot Filter ..................................................................7-35 Check Hoses and Lines..........................................................7-37 E.
Fuel System.................................................................................7-44 Check Water Separator..........................................................7-45 Drain Fuel Tank Sump ...........................................................7-46 Replace Fuel Filter...................................................................7-47 Check Fuel Hoses.....................................................................7-48 F.
Air Cleaner...................................................................................7-49 Boom Swing Power.................................................................5-13 Use Correct Track Shoe...............................................................5-13 Avoid Other Than Specified Machine Operations.............5-14 Precautions for Using Bucket Hook........................................5-15 Boom Cylinder May Hit Blade...................................................5-15 Avoid Hitting Blade with Bucket.............................................5-16 Avoid Colliding Blade Against Rocks.....................................5-16 Avoid Colliding Boom Cylinder with Track .........................5-16 Using Rubber Crawler.................................................................5-17 Pipings for Breaker and Crusher..............................................5-19 Precautions for Breaker Operation.........................................5-20 Precautions for Crusher Operation.........................................5-23 Precautions for After Operating Machine............................5-24 Emergency Boom Lowering Procedure................................5-25 Clean Air Cleaner Element...................................................7-49 Replace Air Cleaner Element...............................................7-49 G.
Cooling System.........................................................................7-51 Check Coolant Level ..............................................................7-53 Check and Adjust Fan Belt Tension...................................7-53 Change Coolant.......................................................................7-56 Clean Radiator..........................................................................7-58 Clean Air Conditioner Condenser......................................7-58 H.
Electrical System......................................................................7-59 Battery.........................................................................................7-59 Replacing Fuses.......................................................................7-63 I.
Miscellaneous.............................................................................7-64 TRANSPORTING ............................................................................6-1 Transporting by Road.....................................................................6-1 Trailer Loading/Unloading...........................................................6-1 Loading................................................................................................6-2 Check Bucket Teeth for Looseness and/or Wear .........7-64 Replace Bucket.........................................................................7-66 Adjust Track Sag (Rubber Crawler) and Check for Damage ................................................................................7-67