CONTENTS Maintenance Guide Table ............................................................ 7-4 Prepare Machine for Maintenance ........................................... 7-6 Hood and Access Covers .............................................................. 7-7 Periodic Replacement of Parts ................................................... 7-8 Maintenance Guide ....................................................................... 7-9 A.
Greasing ......................................................................................7-14 Front Joint Pins .......................................................................7-14 Swing Bearing .........................................................................7-19 Swing Internal Gear ..............................................................7-20 Electric Grease Gun ...............................................................7-21 B.
Engine ..........................................................................................7-29 Engine Oil Level ......................................................................7-29 Change Engine Oil ................................................................7-30 Replace Engine Oil Filter .....................................................7-30 C.
Transmission ..............................................................................7-32 Pump Transmission ...............................................................7-32 Swing Reduction Gear .........................................................7-33 Travel Reduction Gear ..........................................................7-34 D.
Hydraulic System .....................................................................7-36 Inspection and Maintenance of Hydraulic Equipment ...............................................................................7-36 Breaker Maintenance ...........................................................7-38 Check Hydraulic Oil Level ...................................................7-39 Change Hydraulic Oil ...........................................................7-40 Suction Filter Cleaning ........................................................7-40 Replace Hydraulic Tank Oil Filter ......................................7-43 Replace Pilot Oil Filter ..........................................................7-45 Replace Air Breather Element ...........................................7-46 Check Hoses and Lines ........................................................7-47 Service Recommendations for Hydraulic Fittings .....7-50 E.
Fuel System ................................................................................7-52 Drain Fuel Tank Sump .........................................................7-54 Check Water Separator ........................................................7-55 Replace Fuel Main Filter Element .....................................7-59 Replace Fuel Pre-Filter Element .......................................7-60 Clean Fuel Solenoid Pump Strainer ................................7-61 Check Fuel Hoses ...................................................................7-62 F.
Air Cleaner ...................................................................................7-63 Clean the Air Cleaner Outer Element .............................7-63 Replace the Air Cleaner Outer and Inner Elements ...7-63 G.
Cooling System ........................................................................7-65 Check Coolant Level .............................................................7-67 Check and Adjust Fan Belt Tension .................................7-68 Change Coolant .....................................................................7-69 Clean Radiator, Oil Cooler Core and Inter Cooler .......7-70 Clean Oil Cooler, Radiator and Inter Coller Front Screen ................................................................7-70 Clean Air Conditioner Condenser ....................................7-70 Clean Fuel Oil Cooler ...........................................................7-70 Clean Air Conditioner Front Screen (Opt.) ...................7-70 H.
Electrical System ......................................................................7-71 Replace Batteries ...................................................................7-74 Replacing Fuses ......................................................................7-75 I.
Miscellaneous ............................................................................7-77 Check Bucket Teeth ...............................................................7-77 Change Bucket .......................................................................7-80 Adjust the Bucket Linkage (Backhoe) ............................7-81 Remove the Travel Levers ...................................................7-82 Check and Replace Seat Belt Check ................................7-82 Check Windshield Washer Fluid Level ............................7-83 Check Track Sag ......................................................................7-84 Clean and Replace Air Conditioner Filter .....................7-86 Check the Air Conditioner ..................................................7-88 Clean Cab Floor ......................................................................7-89 Retighten Cylinder Head Bolt ...........................................7-90 Inspect and Adjust Valve Clearance ................................7-90 Check Fuel Injection Timing ..............................................7-90 Measure Engine Compression Pressure ........................7-90 Check Starter and Alternator ............................................7-90 Check Water Pump ................................................................7-90 Check Tightening Torque of Bolts and Nuts ................7-91 HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT Hydraulic Circuit .............................................................................
8-1 Electrical Circuit .............................................................................. 8-2 Electrical Diagram .......................................................................... 8-3 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 Impossible to Start the Engine ................................................11-1 Engine ...............................................................................................11-2 Electrical System ...........................................................................11-6 Mode Selection .............................................................................11-8 Control Levers ................................................................................11-9 Hydraulic System ..........................................................................11-9 SPECIFICATIONS Specifications (ZAXIS400R -3 , ZAXIS400LCH -3 ) ...................12-1 Working Ranges (ZAXIS400R -3 , ZAXIS400LCH -3 ) ..............12-2 Bucket Types and Applications (ZAXIS400R -3 , ZAXIS400LCH -3 ) .........................................12-3 Sound Level Results (2000/14/EC) .........................................12-4 Vibration Level ...............................................................................12-4 OPTIONAL ATTACHMENTS AND DEVICES Lifting Capacities ..........................................................................13-1 INDEX ...............................................................................................14-1