Page 1 PART NO. EM1JB-1-1 850LC 870H 870LCH Hydraulic Excavator URL:http://www.hitachi-c-m.com URL:http://www.hitachi-c-m.com PRINTED IN JAPAN (E) 2006, 02 Serial No 20001 and up This book is printed on recycled paper.
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support pro- service your machine correctly. Failure to do so could re- gram for customers who operate and maintain their sult in personal injury or machine damage.
Page 3: Machine Numbers
MACHINE NUMBERS The manufacturing Nos. explained in this group is the individ- ual 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.
Page 4 MACHINE NUMBERS SWING MOTOR TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M1JB-00-001 HYDRAULIC PUMP TYPE AND SERIAL NUMBER TYPE: MFG. NO.: BOOM TYPE AND SERIAL NUMBER M1J7-07-003 TYPE: MFG. NO.: ARM TYPE AND SERIAL NUMBER TYPE: MFG. NO.:...
Page 5 MACHINE NUMBERS BUCKET TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M116-12-004...
Page 6 MACHINE NUMBERS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 7: Table Of Contents
CONTENTS MACHINE NUMBERS Beware of Exhaust Fumes ............S-27 Precautions for Welding and Grinding ......... S-27 Avoid Heating Near Pressurized Fluid Lines ....... S-28 SAFETY Avoid Applying Heat to Lines Containing Recognize Safety Information ........... S-1 Flammable Fluids ..............S-28 Understand Signal Words ............
Page 8 OPERATING THE MACHINE Cab Heater Operation ..............1-72 Control Lever (ISO Pattern) ............5-1 Cooling Operation ...............1-72 Control Lever (HITACHI Pattern) ..........5-2 Defroster Operation ..............1-73 Pilot Control Shut-off Lever ............5-3 Tips for Optimal Air Conditioner Usage .......1-74 Engine Speed Control ..............5-6 AM/FM Radio Operation ............1-75...
Page 9 CONTENTS Retracting the Side Frame ............6-21 Change Coolant ..............7-60 Extending the Side Frame ............6-22 Clean Radiator/ Oil Cooler/ Inter Cooler/ Type of Packings for Transportaion ........6-25 Fuel Cooler Core ..............7-61 Packing Dimensions and Weights for Clean Oil Cooler Front Screen ...........7-61 Transportation-1 (Backhoe) ..........6-26 H.
Page 10 CONTENTS SPECIFICATIONS Specifications (Backhoe) ZAXIS850 , ZAXIS850LC ..........12-1 Working Ranges (Backhoe) ZAXIS850 , ZAXIS850LC ..........12-2 Shoe Types and Applications ...........12-3 ZAXIS850 ................12-3 ZAXIS850LC ................12-3 Bucket Types and Applications (Backhoe) ......12-4 ZAXIS850 , ZAXIS850LC ..........12-4 Specifications (Backhoe) ............12-5 ZAXIS870H , ZAXIS870LCH ..........12-5 Working Ranges (Backhoe) ............12-6 ZAXIS870H...
Page 11: Safety
SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...
Page 12: Follow Safety Instructions
Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equip- ment 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,...
Page 13: Wear Protective Clothing
SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropri- ate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing SA-438 Wet weather gear Respirator or filter mask.
Page 14: General Precautions For Cab
SAFETY 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 ac- cident.
Page 15: Use Handholds And Steps
SAFETY USE HANDHOLDS AND STEPS • 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. •...
Page 16: Fasten Your Seat Belt
SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the opera- tor may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine web- bing, buckle and attaching hardware.
Page 17: Operate Only From Operator's Seat
SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground.
Page 18: Precautions For Operations
SAFETY PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equip- ment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of operation and machine movement.
Page 19: Investigate Job Site Beforehand
SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from fall- ing and to prevent the ground, stockpiles, or banks from collapsing.
Page 20: Equipment Of Head Guard, Rops, Fops
SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure SA-490...
Page 21: Drive Machine Safely
SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine.
Page 22 SAFETY • Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direc- tion must be changed, move the machine to level ground, then, change the direction to ensure safe operation. •...
Page 23: Avoid Injury From Rollaway Accidents
SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. •...
Page 24: Avoid Injury From Back-Over And Swing Accidents
SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: •...
Page 25: Keep Person Clear From Working Area
SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attach- ment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and ma- chine movement.
Page 26: Avoid Tipping
SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA- CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.
Page 27: Dig With Caution
SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines.
Page 28: Avoid Power Lines
SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front at- tachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.
Page 29: Protect Against Flying Debris
SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before strik- ing any object.
Page 30: Transport Safely
SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or un- loading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe trans- portation. • Select an appropriate truck or trailer for the machine to be transported.
Page 31: Practice Safe Maintenance
SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. •...
Page 32: Warn Others Of Service Work
SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
Page 33: Prevent Parts From Flying
SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE AS- SEMBLY.
Page 34: Prevent Burns
SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. •...
Page 35: Avoid High-Pressure Fluids
SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnect- ing hydraulic or other lines. •...
Page 36: Prevent Fires
SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
Page 37: Evacuating In Case Of Fire
SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF po- sition if there is time. • Use a fire extinguisher if there is time. •...
Page 38: Avoid Heating Near Pressurized Fluid Lines
SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pres- surized fluid lines, resulting in severe burns to yourself and bystanders. • Do no heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 39: Beware Of Asbestos Dust
• Keep bystanders out of the work site during operation. SA-029 • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.
Page 40: Handle Chemical Products Safely
• Improperly disposing of waste can threaten the environ- ment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 41: Safety Signs/Europe/Asia/Middle And Near East Model Only
Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. SS-2822 S-31...
Page 42 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only WARNING! Prior to operation, maintenance, disassembling, and trans- portation of the machine, be sure to read and understand the Operator’s Manual. SS-1616 If the parked machine is unexpectedly moved, serious injury or death due to crushing may result. Be sure to lower the front attachment to the ground, lock the control levers, and remove the engine key before leaving the machine unat- tended.
Page 43 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Don’t grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand. SS7371371 If the machine should overturn, the operator may become injured and/or thrown from the cab and/or crushed by the...
Page 44 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only Sign indicates a hazard of being hit by the working device of the machine. Keep away from machine during operation. SS3089581 Sign indicates a hazard of a flying plug from track adjuster that could cause injury. Read manual before adjusting track for safe and proper handing.
Page 45 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine. SS-1614 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
Page 46 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only Sign indicates an electrical hazard from handling the cable. Read manual for safe and proper handling. SS4459714 Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte.
Page 47 SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only SS-1022 REFLECTOR (FOR EUROPEAN STANDARD) SS-1988 Asia/Middle and Near East Model only. SS-710 S-37...
Page 48: Safety Signs/North America And Oceania Model Only
Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. SS-2823 S-38...
Page 49 SAFETY SIGNS/North America and Oceania Model Only SS-862 SS-863 SS-859 S-39...
Page 50 SAFETY SIGNS/North America and Oceania Model Only SS3106039 SS3092349 SS-408 S-40...
Page 51 SAFETY SIGNS/North America and Oceania Model Only SS3077560 SS-1022 When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Don’t grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand.
Page 52 SAFETY SIGNS/North America and Oceania Model Only SS-024 SS-710 SS3089713 S-42...
Page 53: Components Name
COMPONENTS NAME COMPONENTS NAME 1- Bucket 2- Bucket Cylinder 3- Arm 4- Arm Cylinder 5- Boom Cylinder 6- Boom 7- Fuel Tank 8- Counterweight 9- Engine 10- Track 11- Travel Device 12- Hydraulic Oil Tank 13- Front Idler 14- Cab T1JB-01-02-002...
Page 54: Getting On / Off The Machine
GETTING ON / OFF THE MACHINE GETTING ON / OFF THE MACHINE For safety, steps and handrails are provided at various places on the machine. Use them when getting on/off the machine and when inspecting/servicing. WARNING: • When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine.
Page 55: Operator's Station
OPERATOR'S STATION CAB FEATURES Std. Model 1- Left Control Lever/Horn Switch (On Top of Lever) 2- Left Travel Pedal 3- Left Travel Lever 4- Right Travel Lever 5- Right Travel Pedal 6- Right Control Lever/Power Boost Switch 7- Multi Function Monitor Panel 8- Switch Panel 9- Key Switch 10- Air Conditioner Panel...
Page 56 OPERATOR'S STATION CAB FEATURES Machines Equipped with Optional 1- Left Control Lever/Horn Switch (On Top of Lever) 2- Left Travel Pedal 3- Left Travel Lever 4- Right Travel Lever 5- Right Travel Pedal 6- Attachment Pedal (Optional) 7- Right Control Lever/Power Boost Switch 8- Multi Function Monitor Panel 9- Switch Panel 10- Key Switch...
Page 57: Multi Function Monitor
OPERATOR'S STATION MULTI FUNCTION MONITOR How To Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is dis- played. When the key switch is turned to the ON position, the starting screen displays for about two seconds and the basic screen displays.
Page 58: Outline
OPERATOR'S STATION OUTLINE 1 - Work Mode Display 2 - Auto-Idle Display 3 - Overload Alarm Display (Optional) 4 - Auto-Lubrication Display (Optional) 5 - Auxiliary 6 - Preheat Display 7 - Work Mode Display 8 - Hour Meter 9 - Auxiliary 10 - Fuel Gauge 11 - Mail Display (Optional) 12 - Auto-Lubrication Display (Optional)
Page 59 OPERATOR'S STATION • Display of Meters Items to be displayed Work Mode 8. Hour Meter 10. Fuel Consumption Gauge 14. Clock 16. Menu 22. Coolant Temperature Gauge • Work Mode Display The attachments being used are displayed. M1J1-05-001 Digging Mode T1V1-05-01-108 Attachment Mode Breaker...
Page 60 OPERATOR'S STATION • Auto-Idle Display(2) When selecting auto-idle from the switch panel, the auto- idle display (2) is displayed. When the key is turned ON, the data blinks for 10 seconds. • Overload Alarm Display (3) (optional) T1V1-05-02-002 The system measures the load of suspended load from the bottom pressure of boom cylinder.
Page 61: Menu Screen (23)
OPERATOR'S STATION Menu Screen (23) Press menu key (16) on the basic screen to display main menu screen (23). Select the desired menu by operating key (25) lo- cated under keys on icon display area (24). M1J5-05-002...
Page 62: Hour Meter
OPERATOR'S STATION Hour Meter Total (accumulated) machine operation hours counted since the machine started working, are displayed in the unit of HOUR (h). One digit after the decimal point indicates the tenths of an hour (6 minutes). M1U1-01-038 Fuel Gauge The fuel amount in the fuel tank is indicated.
Page 63: Menu Key
OPERATOR'S STATION Menu Key Shifts the basic screen to the menu screen. M1U1-01-042 Optional Function Key The desired preset optional function can be selected by oper- ating these keys even though the menu key is not operated. F1 : Work Mode Selection F2 :Auxiliary M1U1-01-043 F3 : Mail (Optional)
Page 64: Coolant Temperature Gauge
OPERATOR'S STATION Coolant Temperature Gauge Indicates the engine coolant temperature. Normally the needle is around the center of the scale during operation. M1U1-01-047 Operating Status Icon Display Displays icons indicating the current status of the attachment (1) selected at the work mode selection screen and operation modes such as the auto-idle system (2) and the Auto-Lubri- cation (3) and preheat display (4), etc when these systems are activated.
Page 65 Displaying Basic Screen by Password Input (Optional) IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. If the password ever escapes the customer’s memory, the machine must be modified. Be extra careful not to forget the password.
Page 66 OPERATOR'S STATION In Case of Inputting an Incorrect Password 1. If inputting an incorrect password, the message “Pass- word is incorrect. ” displays by pushing the determination key. T1V5-05-01-093 Password Input Screen T1V5-05-01-002 Determination Key Delete Key 2. Return to the password input screen, by pushing the back key.
Page 67 OPERATOR'S STATION 3. If inputting an incorrect password three times, a screen displays informing that the security lock has been ap- plied, and a buzzer rings for thirty seconds. During that time, the buzzer does not stop ringing even if turning of the key switch ON/OFF.
Page 68 OPERATOR'S STATION Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that display the basic screen based upon password input. By using the password duration screen, password duration time can be set. When you restarting the machine, a password need not be input within that timeframe.
Page 69: Alarm Occurrence Screen
OPERATOR'S STATION ALARM OCCURRENCE SCREEN In case any abnormality occurs, the alarm marks are displayed on the basic screen. • When the number of alarms is two or less M1J1-01-007 • When the number of alarms is three or more M1J1-01-008 1-17...
Page 70 OPERATOR'S STATION In case any abnormality occurs, push the key located under the alarm mark. The monitor displays the corrective action to the alarm situation. M1J1-01-007 Push a Relevant Key T1V5-05-01-013 1-18...
Page 71: Contents Of Alarms
Stop operation, check hydraulic oil level, check for leaks etc. T1JB-05-02-001 Engine Warning Alarm Engine or engine related parts are abnormal. Consult your nearest Hitachi dealer. M183-01-080 Engine Oil Pressure Alarm Engine oil pressure has decreased. Immediately stop engine. Check engine oil system and oil level.
Page 72 OPERATOR'S STATION • Fuel Sensor Error Display Fuel Sensor Error Coolant Temperature Sensor Error Display Display When the fuel sensor is faulty or if the harness between fuel sensor and monitor unit is broken, the fuel sensor error dis- play is displayed on the fuel gauge. •...
Page 73: Clock Setting
OPERATOR'S STATION Clock Setting Press menu key (2) on basic screen (1) to display main menu screen (3). Select time set menu (4) by pressing the key located under keys on icon display area and adjust the clock set. Time Adjustment After selecting time set menu (4) by pressing the key locat- M1J1-01-002 ed under...
Page 74: Attachment Selection (Only Machines Equipped With Optional Parts)
OPERATOR'S STATION ATTACHMENT SELECTION (Only Machines Equipped with Optional Parts) IMPORTANT: Select the attachments from the work mode screen. In order to display the work mode screen, push key F1 after basic screen displays, or select from main menu. Selecting an Attachment by Using Key F1 1.
Page 75 OPERATOR'S STATION Selecting an Attachment from Main Menu 1. When the basic screen displays, push the menu key and display main menu. 2. Select work mode from main menu by using keys 1 and 2. Push determination key. Then, the work mode screen displays.
Page 76 OPERATOR'S STATION Attachment Specification Screen Breaker 1 Maximum Pump 2 Flow Rate Maximum Pump Flow Rate L/min Maximum Engine Speed Maximum Engine Speed 1700 Valve Selector Accumulator 2-Speed Selector 2ndary Hydraulic Relief Selector Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) T1JB-05-02-002E Breaker 2 Maximum Pump 2 Flow Rate...
Page 77: Pump 2 Flow Rate Adjustment (Only Machines Equipped With Optional Parts)
OPERATOR'S STATION PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts) IMPORTANT: This operation is effective when attachments are used. 1. When the basic screen displays, push the menu key and display main menu. 2. Select attachment adjustment from main menu by using keys 1 and 2.
Page 78: Displaying Operating Conditions
OPERATOR'S STATION DISPLAYING OPERATING CONDITIONS 1. When the basic screen displayed, push the menu key and display main menu. 2. Select operating conditions from main menu by using keys 1 and 2. Push the determination key. Then, the oper- ating conditions screen displays. 3.
Page 79: Fuel Rate Display/No Display
OPERATOR'S STATION FUEL RATE DISPLAY/NO DISPLAY Fuel Rate Display 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1J1-01-002 2. Select fuel rate display/No display from main menu by using keys 1 and 2. Push the determination key. Then, the fuel rate display/No display screen displays.
Page 80 OPERATOR'S STATION 4. Push key 6, and the fuel rate display will be added to ba- sic screen. T1V5-05-01-119 Key 6 M1J1-01-015 Fuel Rate 1-28...
Page 81 OPERATOR'S STATION Fuel Rate No Display 1. When the basic screen displays, push the menu key and display main menu. Fuel Gauge Menu Key Basic Screen M1J1-01-015 2. Select fuel rate display/No display from main menu by using keys 1 and 2. Push the determination key. Then, the fuel rate display/No display screen displays.
Page 82 OPERATOR'S STATION 4. Push key 6, and return to the basic screen. T1V5-05-01-164 Key 6 Basic Screen M1J1-01-002 1-30...
Page 83 Overload Alarm (Only machines equipped with optional parts) IMPORTANT: When using overload alarm, consult your nearest Hitachi dealer. When the overload alarm switch is turned ON, the system measures load of the suspended load from bottom pressure of the boom cylinder. An alarm message is displayed and buzzer is rung, if overload is detected.
Page 84 OPERATOR'S STATION Password Change (Optional) 1. After the basic screen is displayed, push the menu key in order to display the main menu. Menu Key Basic Screen M1J1-01-002 2. Select password change from main menu by using keys 1 and 2. Push the determination key. Then, the password change screen displays.
Page 85 OPERATOR'S STATION NOTE: If inputting an incorrect password after pushing the determination key, the message “Password is incorrect.” displays. Push the back key and go back to the previous screen, Input the password again. T1V5-05-01-044 Back Key 5. The message “Enter password to be registered. ” displays. Then, input a new password with three or four digits and push the determination key.
Page 86 OPERATOR'S STATION 7. The message “Re-enter password. ” displays. Then, input a new password again and push the determination key. 8. If inputting the password again, push the delete key in order to delete the entered characters. T1V5-05-01-132 Determination Key T1V5-05-01-133 Delete Key 9.
Page 87: Back Monitor Settings
OPERATOR'S STATION BACK MONITOR SETTINGS IMPORTANT: Image displayed on the back monitor is of auxiliary nature at best. When the machine is operated pay thorough attention to sur- rounding situation. Auto-Control: ON Image on the monitor unit when traveling is automatically switched to that of the back monitor.
Page 88 OPERATOR'S STATION Auto-Control: OFF Set automatic switching function of images between moni- tor unit and back monitor when traveling to OFF. 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1J1-01-002 2.
Page 89 OPERATOR'S STATION Switching Image Display • From mirror Image to normal image 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1J1-01-002 2. Select back monitor settings from main menu by using keys 1 and 2.
Page 90 OPERATOR'S STATION 4. Push the back monitor switching key, and normal image is displayed on the screen. T1V5-05-01-120 Back Monitor Selector Normal Image T1V1-05-01-126 1-38...
Page 91 OPERATOR'S STATION • From normal image to mirror image 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1J1-01-002 2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.
Page 92 OPERATOR'S STATION 4. Push the back monitor switching key, and mirror image is displayed on the screen. T1V5-05-01-135 Back Monitor Selector Mirror Image T1V1-05-01-127 1-40...
Page 93 OPERATOR'S STATION Switching Image Format IMPORTANT: If changing the rear view camera to one with PAL image format, change the image format of the back monitor to PAL. 1. When the basic screen displays, push the menu key and display main menu. 2.
Page 94: Maintenance Settings
OPERATOR'S STATION MAINTENANCE SETTINGS 1. When the basic screen displays, push the menu key and display main menu. Menu Key Basic Screen M1J1-01-002 2. Select maintenance settings from main menu by using keys 1 and 2. Push the determination key. Then, the main- tenance settings screen displays.
Page 95 OPERATOR'S STATION Change Interval Settings IMPORTANT: Change interval can only be set when main- tenance information display is set to ON. 1. Select change interval by using keys 1 and 2. 2. Set time for change interval by using keys 3 and 4. Key 1 3.
Page 96 OPERATOR'S STATION Resetting Data If data is reset, push key 5 on the Interval ON/OFF settings screen. The message “Reset Data. OK?” displays. Then, push the de- termination key. The value of remaining hours is reset to that of change in- terval.
Page 97 OPERATOR'S STATION Screen Display when Maintenance Information Display is ON • When only one item displays 1. If turning the key switch to the ON position, the starting screen displays. Then, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds.
Page 98 OPERATOR'S STATION • When more than two items apply 1. If turning the key switch to the ON position, the starting screen displays. Then, the scheduled maintenance screen for the items whose change interval has expired displays for three to ten seconds. Finally the basic screen displays. NOTE: For a machine which the basic screen is displayed ac- cording to a password on, the scheduled maintenance screen for the items whose change interval has expired...
Page 99: Mail (Optional)
IMPORTANT: This function is available only to a ma- chine equipped with a satellite terminal. When using the mail function, consult your nearest Hitachi dealer. 1. When the basic screen displays, push key F3 and display mail screen. 2. If pushing a relevant request key, mail information is sent to ICF.
Page 100 OPERATOR'S STATION NOTE: When satellite terminal could not receive the mail, the message “Mail delivery failed.” is displayed on the screen. T1V5-05-01-040 1-48...
Page 101: Language Settings
OPERATOR'S STATION LANGUAGE SETTINGS 1. When the basic screen displayed, push the menu key and display main menu. 2. Select language from main menu by using keys 1 and 2. Push the determination key. Then, the language settings screen displays. 3.
Page 102 OPERATOR'S STATION Lists of Display Language Display Languages 1 Language Screen Display Japanese T1V1-05-01-141 English T1V1-05-01-142 Chinese (Simplified) T1V1-05-01-143 Chinese (Traditional) T1V1-05-01-144 Korean T1V1-05-01-145 Indonesian T1V1-05-01-146 Thai T1V1-05-01-147 Vietnamese T1V1-05-01-148 Myanmarese T1V1-05-01-149 Arabic T1V1-05-01-150 Persian T1V1-05-01-151 Turkish T1V1-05-01-152 Display Languages 2 Language Screen Display English...
Page 103: Switch Panel
OPERATOR'S STATION SWITCH PANEL 1- Engine Control Dial 2- Auto-Idle Switch 3- Power Mode Switch 4- Travel Mode Switch 5- Work Light Switch 6- Wiper/Washer Switch M1U1-01-015 1-51...
Page 104: Engine Control Dial
OPERATOR'S STATION ENGINE CONTROL DIAL Use engine control dial (1) to adjust engine speed. Fast Idle Turn it clockwise to increase engine speed or counterclockwise to decrease engine speed. • The fully clockwise position : Fast idle Slow Idle • The fully counterclockwise position : Slow idle M1U1-01-033 AUTO-IDLE SWITCH The auto-idle switch (2) sets the engine speed control mode to...
Page 105: Power Mode Switch
OPERATOR'S STATION POWER MODE SWITCH Three engine speed modes, E, P, and H/P modes, are selected by operating the power mode switch. • E (Economy) Mode Although production is slightly reduced more than in the P mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently.
Page 106: Work Light Switch
OPERATOR'S STATION WORK LIGHT SWITCH Work light switch has the following positions: • 1 Position Work light (1) on the base machine will light. Also, the in- strument panel illumination will light. • 2 Position Work light (2) will light in addition. M178-01-015 •...
Page 107: Wiper/Washer Switch
OPERATOR'S STATION WIPER/WASHER SWITCH The wiper and the window washer are operated using the Fast wiper/washer switch. • Wiper Turn the wiper/washer switch to the specified position to operate the wiper. Slow OFF Position: The wiper stops and is retracted. INT Position: The wiper operates intermittently at the interval selected by the switch position as described below.
Page 108: Switch Panel (Optional Included)
OPERATOR'S STATION SWITCH PANEL (Optional included) Armrest NOTE: • There are switches for the standard and option. Be- fore using the switches on the switch panel, make sure what kind of optional devices are equipped. • Raise the armrest when you operate the switch. •...
Page 109 OPERATOR'S STATION Travel Alarm Deactivation Switch (Optional) The travel alarm buzzer sounds during travel operation. When push the travel alarm deactivation switch (1) , the travel alarm buzzer function is deactivated. M1U1-01-035 Seat Heater Switch (Optional) When seat heater switch (2) is turned ON, the seat surface is heated so that the seat section becomes warm.
Page 110 OPERATOR'S STATION Boom Mode Switch When boom mode switch (4) is turned ON, the machine cannot be raised off the ground with the front attachment, reducing machine vibration to be developed during excava- tion. When turned OFF, the machine can be raised off the ground with the front attachment, allowing the machine to evacu- ate if the machine becomes stranded in a muddy area.
Page 111 OPERATOR'S STATION Rotating Light Switch (Optional) When the rotating light switch (8) is turned ON, the rotating light provided at the rear on the cab roof comes ON. M1U1-01-012 Fan Rotating Direction Switch (Optional) When fan rotating direction switch (9) is turned ON, the fan rotates in reverse, and the radiator, the oil cooler, and the inter cooler core can be cleaned.
Page 112: Fan Rotating Direction Device(Optional)
OPERATOR'S STATION FAN ROTATING DIRECTION DEVICE(Optional) When fan rotating direction switch (3) is turned ON, the fan rotates in reverse, and the radiator, the oil cooler, and the inter cooler core can be cleaned. 1. Turn all control levers (1) to neutral with engine running. Then, pull the pilot control shut-off lever (2) up to the LOCK position.
Page 113: Key Switch
OPERATOR'S STATION KEY SWITCH 1- OFF (Engine Off ) 2- ACC (Horn, Radio etc.) 3- ON (Engine On) 4- START (Engine Start) M178-01-049 POWER BOOST SWITCH Power boost switch (5) is used to gain maximum digging pow- er, and is located on the top of the right control lever. M1J1-01-024 HORN SWITCH Horn switch (6) is provided on the top of the left control lever.
Page 114: Cigar Lighter
IMPORTANT: In case cigar lighter (2) does not pop out au- tomatically 30 seconds after pushing cigar lighter (2) in, pull out cigar lighter (2) manu- ally. Then, consult the your nearest Hitachi dealer. 1. Turn key switch (1) to the ACC or ON position.
Page 115: Cab Light
Turn the cab light ON or OFF by using switch (1). M1U1-01-022 INSTALLING FIRE EXTINGUISHER (Optional) A fire extinguisher (2) can be installed at the right rear corner inside the cab. Consult your nearest HITACHI dealer to install a fire extinguisher. M1J1-01-029 1-63...
Page 116: Pilot Control Shut-Off Lever
OPERATOR'S STATION PILOT CONTROL SHUT-OFF LEVER Pilot control shut-off lever (1) functions to prevent the machine from being mistakenly operated when the operator is getting on or off the machine. WARNING: • Pilot control will not be shut-off unless pilot con- trol shut-off lever (1) is completely pulled-up to the LOCK position.
Page 117: Fuse Box
OPERATOR'S STATION FUSE BOX Fuse Box Additional Fuse Box 10- CONTROLLER 20- OPTION3 9- BACKUP 19- SW. BOX 8- ECM 18- POWER ON 7- LUBRICATOR 17- AIRCON 6- OPTION2 16- GLOW. R 5- OPTION1 15- AUXILIARY M1J1-01-021 4- SOLENOID 14- PCV 3- HEATER 13- LIGHTER 2- WIPER...
Page 118: Air Conditioner Operation
OPERATOR'S STATION AIR CONDITIONER OPERATION Features: • Full-Automatic Control Regardless of variations in atmospheric temperature and whether sun light is intense or not, the air temperature at the vent, blower speed, and air in/out vent locations are automatically controlled so that air temperature in the cab is maintained at the temperature set by the temperature control switch.
Page 119: Auto Air Conditioner
OPERATOR'S STATION AUTO AIR CONDITIONER Distinctive Feature • Temperature Control: Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation. • Max. Cooling and Heating: Maximum cooling or heating can be obtained by moving the temperature control switch to the full right or left re- spectively.
Page 120 OPERATOR'S STATION Controller Part Name and Function • Blower OFF Switch (6) Stops the blower. When the switch is pressed, all displays (vent mode, set- temperature, and blower speed) on the LCD (8) panel will disappear and the blower stops in both the auto and manu- al modes.
Page 121 OPERATOR'S STATION • Temperature Control Switch (9) Sets the air temperature in the range of 18 to 32.0 °C (65 to 90 °F) in the MANUAL and AUTO modes. Temperature can be set by 0.5 °C (0.9 °F) increments. The set-temperature is displayed on the LCD (8) center.
Page 122 LCD in order. Press fan OFF-switch (6) to complete the diagnosing function. If any trouble has been found through operating the diagnos- tic function, contact your nearest Hitachi dealer for repair. 1-70...
Page 123 OPERATOR'S STATION • Mode Switch (10) Selects the air vent in the four modes as shown below: : Front/Defroster Vent Mode : Front/Rear/ Defroster Vent Mode : Front/Rear/Foot/ Defroster Vent Mode : Foot Vent Mode M178-01-017 • AUTO Switch (11) Selects the air conditioner operation mode in either AUTO or MANUAL.
Page 124: Cab Heater Operation
OPERATOR'S STATION CAB HEATER OPERATION (Although warm air will flow out of the front/defroster vent, front/rear/defroster vent, or front/rear/foot/defroster vent, normally the foot vent is used for heating opera- tion.) After selecting the foot vent mode by operating mode switch (10), set the desired temperature using temperature control switch (9).
Page 125: Defroster Operation
OPERATOR'S STATION DEFROSTER OPERATION Select either the front/defroster vent mode or the front/ rear/defroster vent mode by operating mode switch (10). Set the maximum heating temperature (32.0 °C, 90 °F) using temperature control switch (9). Press fresh air mode switch (13) to turn the indicator ON.
Page 126: Tips For Optimal Air Conditioner Usage
OPERATOR'S STATION TIPS FOR OPTIMAL AIR CONDITIONER USAGE For Rapid Cooling Temperature in the cab may rise over 80°C (176°F) when the machine is exposed to sun light in the summer. For rapid cooling, ventilate air in the cab first. After starting the engine, set the temperature control to maximum cooling (18°C, 65°F) using temperature control switch (9).
Page 127: Am/Fm Radio Operation
OPERATOR'S STATION AM/FM RADIO OPERATION Controls on the radio 1- Power Switch/Volume Control Knob 2- Tone Adjustment Ring 3- AM/FM Switch 4- Station Presets 5- Tuning Switches 6- Display Mode Change Switch 7- Digital Display 8- Time Set Switches M1G6-01-026 Tuning Procedure •...
Page 128: Digital Clock Setting Procedure
OPERATOR'S STATION Station Presetting Procedure 1. Select the desired station using tuning switches (5). (Refer to the “Tuning Procedure” section.) 2. Press and hold one station preset (4) for more than 1 sec- ond until an electronic tone is heard. Now, the selected station is preset for the selected station preset.
Page 129: Cab Door Release Lever
OPERATOR'S STATION CAB DOOR RELEASE LEVER CAUTION: Open the cab door all the way until it se- curely locks in the latch on the side of the cab. To unlock the door from this position, push down on lever (1). OPENING UPPER FRONT WINDOW M1J1-07-051 (ZAXIS850...
Page 130: Closing Upper Front Window
OPERATOR'S STATION CLOSING UPPER FRONT WINDOW WARNING: Avoid possible injury while closing window. Upper front window comes down very forcefully. Close window only when sitting in the operator's seat. Guide window down slowly. 1. Pull out lock pin (4) to unlock window. 2.
Page 131: Removing And Storing Lower Front Window (Zaxis850 , 850Lc )
OPERATOR'S STATION REMOVING AND STORING LOWER FRONT WINDOW (ZAXIS850 , 850LC WARNING: Take care not to pinch yours fingers when handling the lower front window. 1. Open the upper front window beforehand when remov- ing the lower front window. 2. While pulling the lower front widow inward, raise it to re- move.
Page 132: Opening/Closing Overhead Window (Zaxis850 , 850Lc )
OPERATOR'S STATION OPENING/CLOSING OVERHEAD WINDOW (ZAXIS850 , 850LC Opening 1. Move lock levers (1) toward center of window. 2. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in posi- tion by dampers (3).
Page 133 OPERATOR'S STATION EMERGENCY EXIT (ZAXIS850 , 850LC If the operator’s cab door should not open in an emergency, escape in the following methods: 1. Open the front windows. Escape through the windows. NOTE: See page “OPENING UPPER FRONT WINDOWS” for the opening method of the front windows.
Page 134: Emergency Exit(Zaxis850 , 850Lc )
OPERATOR'S STATION EMERGENCY EXIT (ZAXIS870H , 870LCH If the operator’s cab door should not open in an emergency, escape in the following methods: 1. Break the rear window glass using the emergency evacu- ation tool (1). Then, escape through the broken window. WARNING: Take care not be injured pieces of broken glass.
Page 135: Adjusting The Seat
OPERATOR'S STATION ADJUSTING THE SEAT Seat Height and Angle Adjustment Seat height adjustment range is 60 mm (2.4 in) with steps every 15 mm (0.6 in) (5 positions in total). Moreover, the height of the front part and the rear part of the seat are ad- justed independently, thus allowing the angle of the seat to be adjusted.
Page 136 OPERATOR'S STATION Armrest Adjustment Armrest (5) can be pulled upright by hand to get on and off the machine easily. The angle of armrest (5) can be adjusted to the desired posi- tion by turning adjusting dial (6) located on the bottom of armrest (5).
Page 137: Adjusting The Seat (Heater Seat Optional)
OPERATOR'S STATION ADJUSTING THE SEAT (HEATER SEAT OPTIONAL) Seat Height and Angle Adjustment Seat height adjustment range is 60 mm (2.4 in) with steps every 15 mm (0.6 in) (5 positions in total). Moreover, the height of the front part and the rear part of the seat are ad- justed independently, thus allowing the angle of the seat to be adjusted.
Page 138: Seat With A Built-In Heater
OPERATOR'S STATION Armrest Adjustment Armrest (5) can be pulled upright by hand to get on and off the machine easily. The angle of armrest (5) can be adjusted to the desired posi- tion by turning adjusting dial (6) located on the bottom of armrest (5).
Page 139: Adjusting The Air-Suspension Seat (Optional)
OPERATOR'S STATION ADJUSTING THE AIR-SUSPENSION SEAT (Optional) Seat Height and Angle Adjustment Seat height adjustment range is 60 mm (2.4 in) with steps every 15 mm (0.6 in) (5 positions in total). Moreover, the height of the front part and the rear part of the seat are ad- justed independently, thus allowing the angle of the seat to be adjusted.
Page 140: Seat With A Built-In Heater
OPERATOR'S STATION Armrest Adjustment Armrest (5) can be pulled upright by hand to get on and off the machine easily. The angle of armrest (5) can be adjusted to the desired posi- tion by turning adjusting dial (6) located on the bottom of armrest (5).
Page 141: Adjusting Console Height
OPERATOR'S STATION ADJUSTING CONSOLE HEIGHT Adjust the console height to the operator’s comfort and/or work conditions. Adjusting console height can be achieved us- ing four positions provided vertically at 20 mm intervals. WARNING: Before loosening the console, support the console. Otherwise, the console may suddenly drop, possibly causing personal injury.
Page 142: Seat Belt
OPERATOR'S STATION SEAT BELT WARNING: Be sure to use the seat belt when operat- ing the machine. Before operating the machine, be sure to examine seat belt (1), buckle (2), and attaching hardware. Re- place seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.
Page 143: Break-In
BREAK-IN OBSERVE ENGINE OPERATION CLOSELY IMPORTANT: Be extra cautious during the first 50 hours, until you become thoroughly familiar with the sound and feel of your new machine. 1. Operate the machine only in economy (E) mode and limit the engine horsepower up to about 80 % of full load. 2.
Page 144 BREAK-IN MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 145: Operating The Engine
OPERATING THE ENGINE INSPECT MACHINE DAILY BEFORE STARTING Arm Cylinder Washer Tank Boom Swing Bearing Bucket Cylinder Tool Box • Electric Grease Gun • Auto-Lubrication Device Center Joint Fuel Tank Link B Swing Device Control Valve Boom Cylinder Link A Fan Motor Reservoir Bucket...
Page 146: Before Starting Engine
ON position, return key switch to OFF. Wait for more than 30 seconds (the buzzer stopped), then try again. If the security lock screen is displayed again, contact your nearest HITACHI dealer. Security Lock Screen T1V5-05-01-005...
Page 147: Level Check
OPERATING THE ENGINE LEVEL CHECK 1. Stop machine on firm and surface level ground 2. Turn key switch (1) to the ON position. 3. Raise the armrest, while press and hold engine oil / coolant level switch (2), engine oil level indicator (4) / coolant level indicator (5) are displayed on monitor (3).
Page 148: Starting The Engine In Ordinary Temperature
IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. Slow Idle 7. The basic screen will be displayed on the monitor. Check that the preheat indicator (4) is OFF at this time.
Page 149: Starting In Cold Weather
(ignition block system) is activated, this screen is not dis- played. IMPORTANT: When required to activate the TEN-key func- tion (ignition block system), consult your nearest Hitachi dealer. Slow Idle 7. The basic screen will be displayed on the monitor. The machine will automatically check if preheating is required M1U1-01-033 or not.
Page 150: Check Instruments After Starting
OPERATING THE ENGINE CHECK INSTRUMENTS AFTER STARTING Checking lnstruments through Monitor Functions. After starting the engine, check the following points through the monitor functions. Check that 1. Alternator indicator (1) is off. 2. Engine oil pressure indicator (2) is off. 3.
Page 151: Using Booster Batteries
OPERATING THE ENGINE USING BOOSTER BATTERIES WARNING: • An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Charge the batteries in a well ven.tilated area. Do not continue to use or charge the battery when electrolyte level is lower than specified.
Page 152 OPERATING THE ENGINE Disconnecting the booster batteries 1. Disconnect black negative (–) cable (2) from the machine (Red) frame first. 2. Disconnect the other end of black negative (–) cable (2) from the booster batteries. 3. Disconnect red positive (+) cable (1) from the booster batteries.
Page 153: Stopping The Engine
OPERATING THE ENGINE STOPPING THE ENGINE Engine stop procedure 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn engine control dial (1) to the slow idle position and SA-390 run the engine for 5 minuets to cool the engine. IMPORTANT: Turbocharger may be damaged if the engine is not properly shut down.
Page 154 OPERATING THE ENGINE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 155: Driving The Machine
DRIVING THE MACHINE DRIVE THE MACHINE CAREFULLY IMPORTANT: During freezing weather, park machine on a hard surface to prevent tracks from freezing to the ground. Clean debris from tracks and track frame. If tracks are frozen to the ground, raise tracks using boom, move machine carefully to prevent damage to drive train and tracks.
Page 156: Steering The Machine Using Pedals
DRIVING THE MACHINE STEERING THE MACHINE USING PEDALS WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control ac- tions of the travel pedals will be reversed.
Page 157: Steering The Machine Using Levers
DRIVING THE MACHINE STEERING THE MACHINE USING LEVERS WARNING: In the standard travel position, the front Front Idler idlers are positioned at the front of the machine and the travel motors at the rear. If the travel motors are positioned at the front of the machine, the control ac- tions of the travel levers will be reversed.
Page 158: Travel Mode Switch
DRIVING THE MACHINE TRAVEL MODE SWITCH WARNING: Tipping-over accidents can cause serious personal injury. Do not change travel mode while traveling; especially, changing to the fast mode when descending slopes will create a very dangerous situ- ation. Always stop the machine before changing the travel speed mode.
Page 159: Operating On Soft Ground
DRIVING THE MACHINE OPERATING ON SOFT GROUND • Avoid traveling on very soft ground that does not have sufficient strength to firmly support the machine. • If the machine is operated on very soft ground or be- comes stuck, it may be necessary to clean the track frame area.
Page 160: Towing Machine A Short Distance
DRIVING THE MACHINE TOWING MACHINE A SHORT DISTANCE CAUTION: • Cables, straps, or ropes can break causing serious Soft injury. Do not tow machine with damaged chains, Protecort frayed cables, slings, straps, or wire ropes. • Always wear gloves when handling cable, straps or wire ropes.
Page 161: Operating In Water Or Mud
DRIVING THE MACHINE OPERATING IN WATER OR MUD The machine can be operated in water up to the upper edge of the upper rollers only if worksite footing has sufficient strength to prevent the machine from sinking past the upper edge of the upper roller, and only if the water is flowing slowly.
Page 162: Parking The Machine On Slopes
DRIVING THE MACHINE PARKING THE MACHINE ON SLOPES WARNING: Avoid parking machine on slopes. The machine may tip over, possibly resulting in personal injury. If parking the machine on a slope is unavoidable: • Thrust the bucket teeth into the ground. •...
Page 163: Operating The Machine
OPERATING THE MACHINE OPERATING THE MACHINE CONTROL LEVER (ISO PATTERN) WARNING: Never place any part of body beyond win- dow frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. If window is missing or broken, replace im- mediately.
Page 164: Control Lever (Hitachi Pattern)
OPERATING THE MACHINE CONTROL LEVER (HITACHI PATTERN) WARNING: Never place any part of body beyond win- dow frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. If window is missing or broken, replace im- mediately.
Page 165: Pilot Control Shut-Off Lever
OPERATING THE MACHINE PILOT CONTROL SHUT-OFF LEVER Pilot control shut-off lever (1) functions to prevent misopera- tion of the machine from occurring if the control levers are accidentally moved when leaving the operator's seat or when entering the cab. WARNING: •...
Page 166 OPERATING THE MACHINE Warming-up Operation Warm up the engine coolant as follows: 1. Run the engine with engine control dial (1) turned to the slow idle position. Slow Idle M1U1-01-033 Hydraulic Oil Warm-Up Operation IMPORTANT: Hydraulic components may be seriously damaged if the machine is operated with hydraulic oil temperature below 30°C (86°F).
Page 167 OPERATING THE MACHINE Warming-up the Motor and the Cylinders IMPORTANT: • In cold weather, be sure to thoroughly warm-up the motors and cylinders. • If the hydraulic circuit is continuously re- lieved for a certain amount of time, the temperature in the control valve would rise excessively.
Page 168: Engine Speed Control
OPERATING THE MACHINE ENGINE SPEED CONTROL Increase and decrease the engine speed using engine control dial (1) located on the right console, as illustrated. • Turn engine control dial (1) clockwise to increase the en- gine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.
Page 169: Auto-Idle
OPERATING THE MACHINE AUTO-IDLE With auto-idle selector (3) turned to the A/I ON position, ap- proximately 4 seconds after all control levers are returned to neutral, the engine speed decreases to the auto-idle setting to save fuel consumption. The engine speed will immediately increase to the speed set by engine control dial (2) when any control lever is operated.
Page 170: Work Mode
NOTE: Four work modes shown above are designated as the standard specifications. Up to four attachment modes Breaker 1 other than the digging mode can be designated. Con- sult your nearest Hitachi dealer for adding or changing Maximum Pump Flow Rate L/min Maximum Engine Speed 1700 the designation of the attachment modes.
Page 171: Work Mode Select
OPERATING THE MACHINE WORK MODE SELECT Press menu key (3) on basic screen (1) to display main menu screen (4). Select work mode (5) by operating key on menu screen (4). Then, press determination key (6). Select the work mode matching the work to be done by pressing bottom key (8) on work mode selection screen (7).
Page 172: Power Boost
OPERATING THE MACHINE POWER BOOST The power boost switch (4) is used to gain maximum digging power, and is located on the top of the right control lever. When the power boost switch (4) is pushed, increased front at- tachment power will be supplied for about 8 seconds. M1J1-01-024 5-10...
Page 173: Power Mode
OPERATING THE MACHINE POWER MODE One of three engine speed modes, E, P or H/P mode, can be selected using power mode switch (1). • E (Economy) Mode Even if the engine speed is reduced in the E mode, digging force remains unchanged from that in the P mode.
Page 174: Operating Backhoe
OPERATING THE MACHINE OPERATING BACKHOE 1. Place the bucket teeth on the ground with the bottom of the bucket at a 45 degree angle to the ground. 2. Pull the bucket toward the machine using the arm as the main digging force. 3.
Page 175: Precaution For Arm Roll-In/ Bucket Roll-In Combined Operation
OPERATING THE MACHINE PRECAUTION FOR ARM ROLL-IN/ BUCKET ROLL- IN COMBINED OPERATION WARNING: The bucket teeth will hit the boom if the bucket is rolled in with the arm fully rolled in, as illus- trated. When performing combined operation of arm roll- in/bucket roll-in or when rolling in the bucket with the arm fully retracted, be careful not to hit the boom with the bucket teeth.
Page 176: Operating Tips
OPERATING THE MACHINE OPERATING TIPS WRONG Do not hit the track with the bucket when digging. Whenever possible, position your machine on a level surface. Do not use the bucket as a hammer or pile driver. Do not at- tempt to shift rocks and break walls using swing motion. WARNING: To avoid damaging cylinders, do not strike the ground with the bucket nor use the bucket for tamping with the bucket cylinder fully extended (the...
Page 177: Object Handling
Be sure to consult your autho- rized Hitachi dealer. Check that the specifications of the front and machine to be used meet the specifications shown on the rated lifting load table.
Page 178 OPERATING THE MACHINE 1. Secure sling/chain tightly to the load being lifted. Wear gloves when securing sling/chain. 2. Fasten sling/chain to bucket loop, with the bucket curled and arm retracted. 3. Coordinate hand signals with your signal man before starting. 4.
Page 179: Overnight Storage Instructions
OPERATING THE MACHINE OVERNIGHT STORAGE INSTRUCTIONS 1. After finishing the day’s operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods. Park the machine referring to the “PARKING THE MA- CHINE” in the “DRIVING THE MACHINE” section. 2.
Page 180 OPERATING THE MACHINE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 181: Assembling
ASSEMBLING PRECAUTIONS FOR ASSEMBLING • Worker’s Clothing (1) Wear clothing appropriate for the job. (2) Wear safety equipment such as a hard hat, and safety shoes. • Conferring Work Process Thoroughly confer with all related personnel on the entire work process, the role assigned to each, and precautions to ensure safety.
Page 182 Be sure to use Hitachi original bolts. If the bolt length is too long or short, the bolt will not be tightened correctly, pos-...
Page 183: Precautions For Slinging Work
ASSEMBLING PRECAUTIONS FOR SLINGING WORK • Coordinating Signal System, and Appointing Signal Person Before starting, be sure to coordinate signal system to be used. Appoint one qualified signal person only (if a mul- tiple number of signal persons are used, different signals may confuse the workers, possibly causing an accident).
Page 184: Precautions For Operating Machine
ASSEMBLING PRECAUTIONS FOR OPERATING MACHINE • General Precautions for Operating Machine • Always be seated in the operator’s station when operating the machine. • Before starting the engine, or driving or swinging the ma- chine, check that there are no bystanders or obstructions around the machine.
Page 185: Installing Counterweight
ASSEMBLING INSTALLING COUNTERWEIGHT WARNING: Never allow anyone to enter into the area under the lifted counterweight. 1. Lift counterweight (1) using a crane. 2. Insert the convex bosses of counterweight (1) into holes on the back face of base machine (2). Tighten bolts (3). Tightening torque: 2800 N•m (280 kgf•m, 2025 lbf•ft) 3.
Page 186: Installing Boom Cylinder
ASSEMBLING INSTALLING BOOM CYLINDER IMPORTANT: Take care not to mix up the right and left cyl- inders. Install the cylinder with the cylinder piping positioned downward. 1. Pull out the boom foot pin (2) until the end of the pin is flush with the inside end of the bracket.
Page 187 ASSEMBLING 7. After installing the bottom side of the left-hand boom cylinder to the main frame, lay the rod side of the boom cylinder onto supporting stand (7). 8. Install the right-hand boom cylinder in the same proce- dure as taken in the steps 2 to 5 above. WARNING: •...
Page 188: Installing Boom
ASSEMBLING INSTALLING BOOM Bracket WARNING: Never allow anyone to enter into the area under a lifted boom (2). 1. Pull out the boom foot pin (1) until the end of the pin is flush with the inside end of the right side bracket. 2.
Page 189: Connecting Hoses Between Boom Cylinder And Machine
ASSEMBLING CONNECTING HOSES BETWEEN BOOM CYLINDER AND MACHINE WARNING: • Stop the engine. Move the control levers back and forth, and right and left several times to release the remaining pressure in the hydraulic line. • Before connecting hoses between the boom cylin- der and the machine, gradually loosen bolts secur- ing the covers to the ends of the hydraulic piping Frame...
Page 190: Installing Boom Cylinder Rod
ASSEMBLING INSTALLING BOOM CYLINDER ROD 1. Sling right-hand boom cylinder (3) with a crane. 2. Align the rod-pin bore of the boom cylinder (3) with that of boom (2) by moving the boom cylinder up and down while extending or retracting cylinder rod (1). WARNING: •...
Page 191: Installing Arm
ASSEMBLING INSTALLING ARM WARNING: Never allow anyone to enter into the area under the lifted arm (2). 1. Apply grease to boom (1) and arm (2) connecting pin (3). 2. While slinging arm (2) with a crane, align pin hole (4) of arm (2) with that of boom (1).
Page 192: Connecting Arm Cylinder Rod
ASSEMBLING CONNECTING ARM CYLINDER ROD 1. To prevent seals from damage, bleed the air from the arm cylinder according to the following procedures. (1) Start the engine and run it at slow speed. (2) Sling arm cylinder (2) with a crane. Slowly extend and retract rod (1).
Page 193: Connecting Bucket Cylinder Hoses
ASSEMBLING CONNECTING BUCKET CYLINDER HOSES WARNING: • Stop the engine. Move the control levers back and forth, and right and left several times to release the remaining pressure in the hydraulic line. • Before connecting the bucket cylinder and the pipes on the boom with the hoses, loosen bolts securing the covers to the pipes on the boom to gradually release the trapped oil pressure in the...
Page 194: Installing Bucket
ASSEMBLING INSTALLING BUCKET 1. Install the Unit Type O-rings (only Long Arm Spec) around the bucket bosses at the arm connecting section. (In case using Separate Type O-rings, refer to “O-ring Installation Method” in the maintenance.) Bucket Boss 2. Start the engine. Raise the arm (2) tip approximately 2.5 m (2.7 yd) above the ground.
Page 195: Final Inspection
ASSEMBLING FINAL INSPECTION WARNING: • Air may be trapped in the hydraulic circuit after assembling. Avoid excessively quick operation to prevent the hydraulic components from damage. • Bleed the air trapped in the hydraulic circuit by operating each cylinder several times. (Refer to the page for “Change Hydraulic Oil”...
Page 196: Transporting By Road
TRANSPORTING TRANSPORTING BY ROAD When transporting the machine on public roads, be sure to first understand and follow all local regulations. • When transporting using a trailer, check the width, height, length and weight of the trailer with the machine loaded. •...
Page 197 TRANSPORTING Loading/Unloading WARNING: • Always turn the auto-idle/acceleration switch OFF and power mode switch (E) or (P) when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. • Always select the medium or slow speed mode with the travel mode switch.
Page 198 TRANSPORTING 4. Stop the engine. Remove the key from the key switch. 5. Move the control levers several times until hydraulic pres- sure in the cylinders is released. 6. Pull the pilot control shut-off lever to the LOCK position. 7. Close cab windows, roof vent and door, and cover the ex- haust opening, to prevent entry of wind and water.
Page 199 TRANSPORTING Unloading WARNING: The rear end of the flatbed where it meets the ramp is a sudden bump. Take care when traveling over it. IMPORTANT: Prevent possible damage to the front attach- ment. Always position the arm at 90° to the boom when unloading the machine.
Page 200: Retracting Or Extending The Side Frame
TRANSPORTING RETRACTING OR EXTENDING THE SIDE FRAME WARNING: • Thoroughly remove dirt or pebbles stuck to con- tact areas of the track frame and side frame. Other- wise, mounting bolts may be loosened. • Always extend the side frames when operating the excavator at job sites.
Page 201: Retracting The Side Frame
TRANSPORTING RETRACTING THE SIDE FRAME WARNING: Do not loosen side frame guide, bolts (2) IMPORTANT: Remove and clean mud and gravel from con- tact area of track frame (3) and side frame (4) using compressed air. Required Tools: Power Boost Wrench (including accessories) Torque Wrench (width across flats: 50 mm) Air Compressor (slide surface cleaning) 1.
Page 202: Extending The Side Frame
TRANSPORTING EXTENDING THE SIDE FRAME Required Tools • Slinging Rope (20 mm dia.×8 m, 6×37 Ordinary Z lay Class A, Applicable Max. Load: 3 tons) .....................6 Used * Before slinging, make sure no broken wire strands and/ or kinks exist. •...
Page 203 TRANSPORTING 4. Wind two wire ropes (4) around the front and rear sec- tions (one wire rope on each section) of the side frame. Connect lever block (5) to the ends of each wire rope. Attach soft protectors (6) between the side frame (3) cor- ners and wire ropes (4) to prevent damage to side frame (3) and wire ropes (4).
Page 204 TRANSPORTING WARNING: Be sure to slowly operate the boom. If quickly operated, the lever block and/or wire rope may be damaged and/or fly away, possibly causing severe personal injury. Stay away from the machine when operating the boom. 10. Slightly slacken wire rope tension by operating lever blocks (5) and raise the boom to slightly lower the track frame.
Page 205 TRANSPORTING TYPES OF PACKINGS FOR TRANSPORTATION <Type 1> <Type 2> Basic Machine without Basic Machine without Front Attachment Front Attachment and Side Counterweight Frames Boom Two Side Frames Counterweight Bucket Boom Two Boom Cylinders Four Hydraulic Hoses Bucket Two Side Steps Two Boom Cylinders Four Hydraulic Hoses Two Side Steps...
Page 206: Packing Dimensions And Weights For Transportation-1 (Backhoe)
TRANSPORTING PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-1 (BACKHOE) Base Machine (Without front attachment) CAUTION: When performing combined operation of arm roll-in/bucket roll-in or when rolling in the bucket with the arm fully retracted, be careful not to hit the boom with the bucket teeth. Weight : ZX850 49700 kg (109600 lb) ZX850LC...
Page 207 TRANSPORTING Boom Overall Boom Length Weight Width m (ft•in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 7.10 (23’4”) 7490 2700 1450 7670 BE-Boom (24’7”) (8’10”) (4’9”) (16900) 8.40 (27’7”) 8780 2500 1450 8200 (28’10”) (8’2”) (4’9”) (18100) 8.40 (27’7”) 8780 2500 1450...
Page 208 TRANSPORTING Boom Cylinder Weight: 850 kg × 2 (1870 lb × 2) 2890 mm (9’6”) 575 mm (1’11”) M17V-06-026 Hose Weight: 13 kg × 2 (29 lb × 2) 1540 mm (5’ 1”) 9 kg × 2 (20 lb × 2) 1540 mm (5’...
Page 209: Packing Dimensions And Weights For Transportation-2 (Backhoe)
TRANSPORTING PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-2 (BACKHOE) Base Machine (Without front attachment, side frame, steps on the hydraulic oil tank side and hand rails on the right- hand frame, the fuel tank upper and lubricator upper.) Weight : ZX850-3/850L 27400 kg (60400 lb) ZX870H-3/870LCH 27600 kg (60800 lb)
Page 210 TRANSPORTING Counterweight Weight: 13300 kg (29300 lb) (2’4”) Height: 1620 mm (5’4’) 3360 mm (11’ 0”) M1JB-06-003 Boom Overall Boom Length Weight Width m (ft×in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 7.10 (23’4”) 7490 2700 1450 7670 BE-Boom (24’7”) (8’10”) (4’9”)
Page 211 TRANSPORTING Bucket Bucket Capacity Overall Weight (PCSA Heaped) mm (ft•in) mm (ft•in) Width kg (lb) mm (ft•in) 2.9 (3.79) 2210 1910 1780 2700 (7’3”) (6’3”) (5’10”) (5950) 3.5 (4.58) 2210 1910 2040 2950 (7’3”) (6’3”) (6’8”) (6500) 2320 2000 2190 3970 4.5 (5.89 (for BE Front)
Page 212 TRANSPORTING Side Step on the Track Frame 580 mm (1’11”) Weight: 29 kg × 4 (64 lb × 4) 13 kg × 4 (29 lb × 4) 290 mm (11.4”) Height: 125 mm (4.9”) 580 mm (1’11”) 90 mm (3.5”) M162-06-014 6-32...
Page 213: Maintenance
IMPORTANT: • Use only recommended fuel and lubri- cants. • Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown. • Use only genuine HITACHI parts.
Page 214: Check The Hour Meter Regularly
• Lubricate, make service checks and adjustments at inter- vals shown on periodic maintenance guide table. (See page 7-6) USE CORRECT FUELS AND LUBRICANTS IMPORTANT: Always use recommended fuels and lubri- cants. Failure to do so will result in machine dam- age and loss of Hitachi product warranty.
Page 215: Prepare Machine For Maintenance
MAINTENANCE PREPARE MACHINE FOR MAINTENANCE Before performing the maintenance procedures given in the following chapters, park the machine as described below, un- less otherwise specified. 1. Park the machine on a level surface. W1JB-01-04-002 2. Lower the bucket to the ground. 3.
Page 216: Hood And Access Covers
MAINTENANCE HOOD AND ACCESS COVERS Catch WARNING: • Do not keep the hood and access covers open when the machine is parked on a slope, or while the wind is blowing hard. The hood or access cov- ers may close accidentally, possibly resulting in personal injury.
Page 217: Periodic Replacement Of Parts
MAINTENANCE PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspec- tion of the machine. In addition, the parts listed below, if de- fective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone.
Page 218: Maintenance Guide
3. Engine oil Filter Replacement ★ NOTE: ★ Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more. Consult your nearest Hitachi dealer for the detail. C. TRANSMISSION OIL (See Page 7-24) Interval (hours)
Page 219 MAINTENANCE D. HYDRAULIC SYSTEM (See Page 7-29) Interval (hours) Parts Quantity 500 1000 1500 2500 4000 1. Check Hydraulic Oil Level 2. Drain Hydraulic Oil Tank Sump 3. Change Hydraulic Oil 790 L (209 US gal) ✸ ✸ ✸ 4. Suction Filter Cleaning When changing hydraulic oil 5.
Page 220 MAINTENANCE H. AIR CONDITIONER (See Page 7-62) Interval (hours) Parts Quantity 1000 2000 Cleaning 1. Circulating Air Filter Replacement When excessively restricted Cleaning Fresh Air Filter Replacement 2. Check Refrigerant (Gas) Quantity 3. Check Compressor Belt Tension 4. Clean Condenser Core 5.
Page 221: Greasing
MAINTENANCE A. GREASING Interval (hours) Parts Quantity 1000 2000 1 Front Joint Boom Pivot Pins Boom Cylinder ★ Bottom End Bucket and Link Pins Backhoe ★★ Others Backhoe ★ 2. Swing Bearing 3. Swing Internal Gear NOTE: ★ Grease every 10 hours for first 100 hours. ★★...
Page 222 MAINTENANCE AUTOMATIC LUBRICATION --- IF EQUIPPED The automatic lubrication device uses a controller-built-in, grease-tank-attached electric pump (1) to automatically lubri- cate the greasing points on the front attachment at intervals. Turn auto lubrication switch (2) ON, then confirm that auto lubrication indicators (4), (5) display.
Page 223 MAINTENANCE Adding Grease Via Grease Fittings Using Grease Gun: Add grease into the grease tank (6) via the grease fitting lo- cated on the top of the tank using a electric grease gun. Note that grease may not be able to added via the grease fit- ting in cold weather as grease becomes hard.
Page 224: Front Joint Pins (Backhoe)
MAINTENANCE Front Joint Pins (BACKHOE) Bucket and Link Pins --- every 10 hours Vertical M1J1-07-057 Others --- every 50 hours (every 10 hours for first 100 hours) This machine can be lubricated through grease fittings without using the auto lubrication device by following the procedure below.
Page 225 MAINTENANCE • Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin. (Centralized greasing system) (When the auto lubrication device is not used) M162-07-005 • Bucket and Link Pins every 10 hours M1J1-07-058 7-13...
Page 226: Swing Bearing
MAINTENANCE Swing Bearing --- every 500 hours WARNING: Lubricating both the swing bearing and gear and rotating the upperstructure must be done by one person. Before you lubricate the swing bear- ing, clear the area of all persons. Each time you leave the cab •...
Page 227 MAINTENANCE ELECTRIC GREASE GUN --- IF EQUIPPED WARNING: The electric grease gun is not a water- proof type. Don’t expose the grease gun to rain and water. Refrain from using the grease gun while rain- ing. Failure to do so may cause unexpected trouble such as an electricity leak.
Page 228 MAINTENANCE Greasing IMPORTANT: When grease is sufficiently supplied in a closed section, the motor speed becomes slow. Release switch (1) to end greasing. If grease is kept supplied further, seizure of the motor may result. 1. Pull switch (1) to drive the motor. Grease will be delivered from nozzle (3).
Page 229 MAINTENANCE LUBRICATOR --- IF EQUIPPED 1. Lubricator Operation (1) Turn power switch (8) ON to activate the pump (1). Grease is sucked up and supplied to high-pressure grease gun (3). IMPORTANT: When the pump begins to suck grease, any air inside pump (1) will be mixed in, making grease turn whitish.
Page 230 MAINTENANCE 2. Grease Container Replacement When the grease container becomes empty, follow the procedure below to replace it. IMPORTANT: When replacing the grease container, be sure that no sand or debris sticks to suction tube (5) or to follower plate (3). If foreign matter, such as sand, gets into grease, damage to the pump and to parts being lubricated will result.
Page 231: Swing Internal Gear
MAINTENANCE Swing Internal Gear --- every 500 hours WARNING: Adding or changing swing internal gear grease and rotating the upperstructure must be done by one person. Before you start, clear the area of all persons. Each time you leave the cab •...
Page 232: Engine Oil
57 L (15.1 US gal) 3. Engine oil Filter Replacement Recommended Engine Oil IMPORTANT: Use only genuine Hitachi engine oil as shown below or engine oil equivalent to DH-1 spec- ified in JASO. Failure to do so may deterio- rate the engine performance and/or shorten the engine service life.
Page 233: Engine Oil Level
MAINTENANCE Engine Oil Level --- check daily IMPORTANT: For most accurate readings, check the oil level every day before starting the machine. Be sure the machine is on a level surface. 1. Remove dipstick (1). Wipe oil off with a clean cloth. Rein- sert dipstick (1).
Page 234: Change Engine Oil
MAINTENANCE Change Engine Oil --- every 500 hours IMPORTANT: Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more. Replace Engine Oil Filter --- every 500 hours IMPORTANT: Change 250 operating hours, if the content of sulfur of fuel is 2000 ppm or more.
Page 235 MAINTENANCE 14. Open the right access cover and secure the cover with rod. 15. Remove the filter cartridges of engine oil filter (6) by turn- ing it counterclockwise with the filter wrench. 16. Clean the filter gasket contact area on the engine. 17.
Page 236: Transmission Oil
MAINTENANCE C. TRANSMISSION OIL Interval (hours) Parts Quantity 1000 2000 Oil Level Check — 1. Pump transmission Change 6.2 L (1.6 US gal) (Engine oil) Clean Air Breather Oil Level Check 2. Swing Reduction Gear (Gear oil) Change 15 L×2 (4.0 US gal×2) Oil Level Check 3.
Page 237: Pump Transmission
MAINTENANCE Pump Transmission Check Oil Level --- every 250 hours 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. W1JB-02-03-006 IMPORTANT: The turbocharger may be damaged if the en- gine is not properly shut down.
Page 238: Swing Reduction Gear
MAINTENANCE Swing Reduction Gear Check Oil Level --- every 250 hours 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. IMPORTANT: The turbocharger may be damaged if the en- W1JB-02-03-006 gine is not properly shut down.
Page 239: Travel Reduction Gear
MAINTENANCE Travel Reduction Gear Air Release Plug 1 (oil Supply Plug) Check Oil Level --- every 250 hours Oil Level Check 1. Park the machine on a level surface. Plug 2 2. Rotate the travel motor until the imaginary line through plug (1) and plug (3) is vertical.
Page 240 MAINTENANCE Change Gear Oil --- every 2000 hours 1. Park the machine on a level surface. 2. Rotate the travel motor until the imaginary line through plug (1) and plug (3) is vertical. 3. Lower the bucket to the ground. 4.
Page 241: Hydraulic System
Temp. (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F) (–4 to 104°F) (14 to 104°F) Manufacturer Hitachi Super EX 46HN Idemitsu Kosan Super Hydro 46 WRHU British Petroleum Bartran HV46 Caltex Oil Rando Oil HD46 Texaco INC.
Page 242: Inspection And Maintenance Of Hydraulic Equipment
MAINTENANCE INSPECTION AND MAINTENANCE OF HYDRAULIC EQUIPMENT IMPORTANT: Do not adjust the engine governor and/or hydraulic components. WARNING: During operation, the parts of the hydrau- lic system become very hot. Allow the machine to cool down before beginning in- spection or maintenance. 1.
Page 243 MAINTENANCE 5. When adding hydraulic oil, always use the same brand of oil; do not mix brands of oil. As the machine is filled with Super EX 46HN when it is shipped from the factory, use it as a general rule. When selecting to use another brand of oil listed in the table “Brand names of recommended hydraulic oil”, be sure to completely replace the oil in the system.
Page 244: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- daily IMPORTANT: Never run the engine without oil in hydraulic oil tank. 1. Park the machine on a level surface. 2. (Backhoe) Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended. W1JB-02-03-006 3.
Page 245: Drain Hydraulic Oil Tank Sump
MAINTENANCE Drain Hydraulic Oil Tank Sump --- every 250 hours WARNING: Hydraulic oil may be hot just ater opera- tion. Be sure to wait for oil to cool before starting work. IMPORTANT: Never run the engine without oil in hydraulic oil tank.
Page 246: Change Hydraulic Oil
MAINTENANCE Change Hydraulic Oil Suction Filter Cleaning --- every 4000 hours, 2500 hours or 1500 hours WARNING: Hydraulic oil may be hot. Wait for oil to W1JB-04-02-016 cool before starting work. IMPORTANT: Hydraulic oil changing intervals differ ac- cording to kind of hydraulic oils used. (See Recommended Oil Chart in this group) 1.
Page 247 MAINTENANCE 9. Leave the machine for a while after stopping operation. After the oil temperature is cooled, push air bleed valve (6) to bleed air from the hydraulic oil tank. 10. Remove cover (2). 11. Remove oil using a suction pump. The hydraulic oil tank capacity, up to specified oil level, is approximately 420 liter (111 US gal) 12.
Page 248 MAINTENANCE 17. Install cover (2). After removing cap (1), make sure suc- tion filter and rod assembly (4) is in correct position. Tighten the bolts to 50 N•m (5.1 kgf•m, 37 lbf•ft). 18. Add oil until it is between the marks on the sight gauge. IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started.
Page 249: Replace Hydraulic Oil Tank Filter
MAINTENANCE Replace Hydraulic Oil Tank Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just ater opera- tion. Be sure to wait for oil to cool before starting work. 1. Park the machine on a level surface. W1JB-02-03-006 2.
Page 250: Replace Pump Drain Filter
MAINTENANCE Replace Pump Drain Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just ater opera- tion. Be sure to wait for oil to cool before starting work. 1. Park the machine on a level surface. W1JB-02-03-006 2. Lower the bucket to the ground. 3.
Page 251: Replace Pilot Oil Filter
MAINTENANCE 7 Replace Pilot Oil Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just ater opera- tion. Be sure to wait for oil to cool before starting work. 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3.
Page 252: Replace Air Breather Element
MAINTENANCE 8 Replace Air Breather Element --- every 4000 hours WARNING: Hydraulic oil may be hot just after opera- tion. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work. W1JB-02-03-006 Replacement Procedures 1.
Page 253: Check Hoses And Lines
MAINTENANCE 9 Check Hoses and Lines --- daily --- every 250 hours WARNING: Escaping fluid under pressure can pen- etrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Take care to protect hands and body from high-pres- sure fluids.
Page 254 (Use proper bend radius) Hose ends and Deformation or Replace fittings Corrosion (10) NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. M115-07-147 M115-07-148 M115-07-149 Fig.1 7-42...
Page 255 Replace Deformation Replace Loose Retighten NOTE: Refer to the illustrations in Fig.2 for each check point location or for a description of M137-07-007 the abnormality. Use genuine Hitachi parts Fig.2 Table 3. Oil cooler Interval(hours) Check Points Abnormalities Remedies Every 250 hours...
Page 256: Service Recommendations For Hydraulic Fittings
MAINTENANCE SERVICE RECOMMENDATIONS FOR HYDRAULIC FITTINGS Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) An O-ring is used on the sealing surfaces to prevent oil leak- age. 1. Inspect fitting sealing surfaces (6). They must be free of dirt or defects.
Page 257 MAINTENANCE Metal Face Seal Fittings Fittings are used on smaller hoses and consist of a metal flare and a metal flare seat. 1. Inspect flare (10) and flare seat (9). They must be free of dirt or obvious defects. IMPORTANT: Defects in the tube flare cannot be repaired. Overtightening a defective flare fitting will not stop a leak.
Page 258: Fuel System
MAINTENANCE E. FUEL SYSTEM Tank capacity 725 liter (172 US gal) Interval (hours) Parts Quantity 1000 2000 1. Drain Fuel Tank Sump 2. Check Water Separator 3. Replace Main Fuel Filter 4. Replace Fuel Pre-Filter 5. Clean Feed Pump Strainer for leaks.
Page 259 MAINTENANCE 8. To avoid condensation, fill the tank at the end of each day’s operation. Take care not to spill fuel on the machine or ground. Fuel tank capacity is 1120 liters (296 US gal). Do not fill the tank more than specified. Stop filling when a yellow mark on fuel level gauge (3) becomes visible.
Page 260 MAINTENANCE 1 Drain Fuel Tank Sump --- daily 1. Park the machine on a level surface with the upperstruc- ture rotated 90° for easier access. 2. Lower the bucket to the ground. 3. Turn the auto-idle off. IMPORTANT: The turbocharger may be damaged if the en- gine is not properly shut down.
Page 261: Check Water Separator
MAINTENANCE 2 Check Water Separator --- daily (Before staring operation) Water separator separates any water that may get mixed with the fuel. Water separator contains a float which rises as water accumulates. Be sure to drain the sediment when the float rises up to the “Drain Water”...
Page 262 MAINTENANCE Draining Procedures (Pre-Filter) 1. Place 0.5 liters (0.5 US qt) or larger capacity container un- der drain plug (5) to collect the drained water. 2. Shut off the fuel supply by closing cock on the bottom of the fuel tank. 3.
Page 263 MAINTENANCE Air Bleeding Procedures Fuel cock IMPORTANT: Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the water separator, replacing the fuel filter, cleaning the fuel solenoid pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system.
Page 264: Replace Fuel Main Filter Element
MAINTENANCE 3 REPLACE FUEL MAIN FILTER ELEMENT --- every 500 hours IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel cartridge and the pre- cartridge. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.
Page 265: Replace Fuel Pre-Filter Element
MAINTENANCE 4 REPLACE FUEL PRE-FILTER ELEMENT --- every 500 hours IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel cartridge and the pre- cartridge. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.
Page 266: Clean Feed Pump Strainer
MAINTENANCE 5 Clean Feed Pump Strainer --- every 500 hours 1. Remove the feed pump (2) inlet hose joint bolt (1), lo- cated at the water separator inlet. 2. Remove strainer (3) from joint bolt (1) using a screw driv- 3.
Page 267: Check Fuel Hoses
(Use proper bend radius) Hose ends and fittings Deformation or Replace M137-07-005 Corrosion (7) NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. M137-07-006 Fig. 1 7-55...
Page 268: Air Cleaner
MAINTENANCE F. AIR CLEANER Clean the Air Cleaner Outer Element --- every 250 hours or when the restriction indicator comes ON Replace the Air Cleaner Outer and Inner Elements --- after cleaning six times or after one year 1. Park the machine on a level surface. 2.
Page 269: Cooling System
MAINTENANCE G. COOLING SYSTEM Interval (hours) Parts Quantity 1000 2000 1. Check Coolant Level 2. Change Coolant 116 L (31 US gal) Twice a year ✸ Outside 3. Clean Radiator, Oil Cooler, In- ter Cooler, Fuel Cooler Core Inside Once a year 4.
Page 270 MAINTENANCE Antifreeze Mixing Table Refill capacities Mixing Air temperature ratio Antifreezes Soft water ° C ° F liters US gal liters US gal –1 34.8 81.2 21.5 –4 34.8 81.2 21.5 –7 34.8 81.2 21.5 –11 34.8 81.2 21.5 –15 40.6 10.7 75.4...
Page 271 MAINTENANCE 1 Check Coolant Level --- daily Radiator Upper Cover WARNING: Do not loosen radiator filler cap (1) unless the system is cool. Loosen the cap slowly to the stop. Release all pressure before removing the cap. With the engine cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2).
Page 272: Change Coolant
2 Change Coolant --- twice a year (in spring and autumn) NOTE: Before leaving the Hitachi Factory, the cooling system is filled with a mixture of water and Genuine Hitachi Long-Life Coolant. As long as Genuine Hitachi Long-Life Coolant is used,...
Page 273: Clean Radiator/ Oil Cooler/ Inter Cooler/Fuel Cooler Core
MAINTENANCE Inter Cooler Oil Cooler Fuel Cooler 3 Clean Radiator/ Oil Cooler/ Inter Cooler/ Fuel Cooler Core --- every 500 hours WARNING: Use reduced compressed air pressure for cleaning purposes. Clear the area of bystanders, guard against flying chips, and wear personal protec- tion equipment including eye protection.
Page 274: Air Conditioner
MAINTENANCE H. AIR CONDITIONER Interval (hours) Parts Quantity 1000 2000 Cleaning 1. Circulating Air Filter Replacement When excessively restricted Cleaning Fresh Air Filter Replacement 2. Check Refrigerant (Gas) Quantity 3. Check Compressor Belt Tension 4. Clean Condenser Core 5. Check Looseness at each of Fastened Ar- —...
Page 275: Clean And Replace Air Conditioner Filter
MAINTENANCE 1 Clean and Replace Air Conditioner Filter Clean Filter Circulating Air Filter --- every 250 hours Fresh Air Filter --- every 250 hours Replace Filter Circulating Air Filter --- When excessively restricted Fresh Air Filter --- every 1000 hours Removing Fresh Air Filter 1.
Page 276 MAINTENANCE WARNING: Use reduced compressed air pressure (less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes. Clear the area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. Cleaning Clean both the external and internal filters by blowing com- pressed air or washing with water.
Page 277: Check Refrigerant (Gas) Quantity
MAINTENANCE 2 Check Refrigerant (Gas) Quantity --- every 250 hours WARNING: DO NOT allow liquid refrigerant to contact eye or skin. Liquid refrigerant will freeze eye or skin on contact. Be careful not to loosen connections in the air conditioning circuit. Insufficient refrigerant quantity will reduce cooling capacity of the air conditioner.
Page 278: Clean Condenser Core
MAINTENANCE 4 Clean Condenser Core --- every 500 hours WARNING: Always wear safety glasses or goggles when using compressed air to clean condenser core. IMPORTANT: High-pressure air or water can damage con- denser fins. Condenser is located in front of the oil cooler. Clean the con- denser core with water or steam.
Page 279: Check In-Season And Off-Season
MAINTENANCE 6 Check In-Season and Off-Season --- twice a year WARNING: Do not attempt to loosen connections in air conditioning circuit when the air conditioner mal- functions. Doing so may cause high pressure gas to spout, resulting in serious injury. Consult your autho- rized dealer immediately.
Page 280: Electrical System
MAINTENANCE I. ELECTRICAL SYSTEM Interval (hours) Parts Quantity 1000 2000 Level Check Every month 1. Battery Specific Gravity Every month 2. Replace Fuse Replacement — As required WARNING: Improper radio communication equip- ment and associated parts, and/or improper installa- tion of radio communication equipment effects the machine's electronic parts, causing involuntary move- ment of the machine.
Page 281: Batteries
MAINTENANCE 1 Batteries WARNING: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check the battery electrolyte level. Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.
Page 282 MAINTENANCE If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or veg- etable oil. 3. Get medical attention immediately. IMPORTANT: Add water to batteries in freezing weather before you begin operating your machine for the day, or else charge the batteries.
Page 283 MAINTENANCE Electrolyte Level Check --- every one month 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. 3.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.
Page 284: Replace Batteries
MAINTENANCE Check electrolyte specific gravity WARNING: Battery gas can explode. Keep sparks and If you spill acid on yourself: flames away from batteries. Use a flashlight to check 1. Flush your skin with water. the battery electrolyte level. 2. Apply baking soda or lime to help neutralize the acid.
Page 285: Replacing Fuses
MAINTENANCE 1 REPLACING FUSES If any electrical equipment fails to operate, first check the fuses. Fuse box is located behind the operator’s seat. A fuse lo- Fuse Box Additional Fuse Box cation/specification decal is attached to the fuse box cover. Remove the fuse box cover by lifting it upward.
Page 286 MAINTENANCE • Fusible Link (Main Fuse) In case the starter will not rotate even if the key switch is turned to the START position, fusible link may the cause of the trouble. Open the front left side cover to check the fuse. Replace it if blown.
Page 287: Miscellaneous
MAINTENANCE J. MISCELLANEOUS Interval (hours) Parts Quantity 1000 2000 4000 1. Check Bucket Teeth for Wear and Looseness — 2. Change Bucket — As required 3. Adjust Bucket Linkage As required 4. Remove Travel Levers As required 5. Check and Replace Seat Belt Every 3 years (Replace) 6.
Page 288: Check Bucket Teeth
MAINTENANCE 1 Check Bucket Teeth --- daily ZAXIS850 Check the bucket teeth for wear and looseness Replace the point when it has worn to the front end of ESCO marks on the side faces of the point, or to the allowable limit shown in the following table.
Page 289 MAINTENANCE (d) Pull tooth point (1) to remove, turning it counterclock- wise. (e) Remove plug (5) from adapter nose (4). Inspect the plug rubber part for cracks and replace with new one if necessary. IMPORTANT: As a general rule, the life of the locking pin and plug can cover point replacement of several times.
Page 290 MAINTENANCE (d) Insert locking pin (3) between the tooth point and adapter nose with beveled end (7) down and concav- ity (6) facing towards plug (5). Use a hammer to drive in locking pin (3) fully with its top flush with adapter (2) surface. (In this position, concavity (6) on locking pin (3) is engaged with plug (5) in the adapter nose.) M113-07-081...
Page 291 MAINTENANCE ZAXIS870H-3 Check bucket teeth for wear and looseness Replace teeth if tooth wear exceeds the designated service limit shown below. Dimension A in mm (ft•in) Dimension A mm (ft•in) Part no. Small holes appear RIGHT Neww Limit of Use WRONG 4130932 350 (1’2“)
Page 292 MAINTENANCE 3. Check the pin lock and rubber lock for wear or cracks and replace with a new one if necessary. 3.1 Pin lock Service Limits 1/3T The wear limit of the pin lock is 1/3 the tooth point thickness, as illustrated in the right figure. Earlier re- placement of the pin lock is recommended.
Page 293 Pin Lock M112-07-098 NOTE: When the tooth point comes in contact with the pin lock, as shown in the right figure, the service life of the Tooth Point Pin Lock nose has finished. Consult your authorized Hitachi dealer. M112-07-099 7-81...
Page 294: Change Bucket
MAINTENANCE 2 Change Bucket WARNING: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses, and safety equipment appropriate to the job. Separation Section 1. Park the machine on a level surface. Lower the bucket to the ground and position it with the flat surface resting on the ground.
Page 295: Adjust The Bucket Linkage (Backhoe)
MAINTENANCE 3 Adjust the Bucket Linkage (Backhoe) When play in the linkage increases, remove and install shims as follows: 1. Park the machine on a level surface. Lower the bucket to Clearance the ground with the flat side down so that the bucket will Adjust Part not roll.
Page 296: Remove The Travel Levers
MAINTENANCE 4 Remove the Travel Levers The travel levers may be removed if desired. 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Turn the key switch OFF. Remove the key. 5.
Page 297: Check Track Sag
MAINTENANCE 7 Check Track Sag --- every 50 hours Swing the upperstructure 90° and lower the bucket to raise the track off the ground as shown. Keep the angle between the boom and arm 90 to 110° and position the bucket’s round side on the ground. Place blocks under the machine frame to support the machine.
Page 298 MAINTENANCE Loosen the Track WARNING: Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the ad- justing cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it before loosening.
Page 299: Clean Cab Floor
MAINTENANCE 8 Clean Cab Floor --- as necessary IMPORTANT: When cleaning the cab floor with tap water, spray the floor only. Take care not to splash the surrounding area. Do not increase water spray speed by restricting the hose end, and do not use high pressure steam for cleaning.
Page 300: Check Tightening Torque Of Bolts And Nuts
MAINTENANCE 9 Check Tightening Torque of Bolts and Nuts --- every 250 hours (first time after 50 hours) Check tightness after the first 50 hours then every 250 hours. Tighten to torque shown if any are loose. Bolts and nuts should be replaced with those of the same or higher grade.
Page 301 MAINTENANCE Torque Specifications Bolt Dia Torque Wrench Descriptions Q’ty Size (mm) N•m (kgf•m) (lbf•ft) STD, H (95) (700) 21 Lower roller mounting bolt LC, LCH (95) (700) STD, H 2000 (200) (1475) 22 Track shoe bolt LC, LCH 2000 (200) (1475) 1400 (140)
Page 302 MAINTENANCE Tightening Torque Chart Hexagon Wrench Bolt Dia. Wrench Size M552-07-090 M552-07-091 M157-07-225 Size Socket Bolt N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) (3.1) (22) (2.0) (15.0) (1.0) (7.4) (6.6) (48) (5.1) (37) (2.0) (15.0) (11.0) (81) (9.2) (66) (3.6) (26.0)
Page 303 MAINTENANCE 7-91...
Page 304 MAINTENANCE 3. Retighten radiator mounting bolts. Tool: 41 mm Torque: 1050 N•m (105 kgf•m, 770 lbf•ft) M1JB-07-011 4. Retighten oil cooler mounting bolts Tool: 36 mm Torque: 950 N•m (95 kgf•m, 700 lbf•ft) M1JB-07-021 5. 6. Retighten hydraulic oil and fuel tank mounting bolts. Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft)
Page 305 MAINTENANCE 7. Retighten ORS fittings for hydraulic hoses and piping. Tool: 36 mm Torque: 180 N•m (18 kgf•m, 135 lbf•ft) Tool: 41 mm Torque: 210 N•m (21.5 kgf•m, 155 lbf•ft) M1JB-07-004 M162-07-067 8. Retighten pump transmission mounting bolt Tool: 19 mm Torque: 110 N•m (11 kgf•m, 80 lbf•ft) M1JB-07-005 9.
Page 306 MAINTENANCE 10. Fan pump mounting bolt Tool: 14 mm Hexagonal Socket Wrench Torque: 210 N•m (21 kgf•m, 155 lbf•ft) M1JB-07-054 11. Fan motor mounting bolt Tool: 19 mm Torque: 110 N•m (11 kgf•m, 80 lbf•ft) M1JB-07-053 12. Retighten control valve mounting bolts. Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft)
Page 307 MAINTENANCE 14. Retighten swing device mounting bolts. Tool: 36 mm Torque: 950 N•m (95 kgf•m, 700 lbf•ft) M1JB-00-001 15. Retighten swing motor mounting bolts. Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft) 16. Retighten battery mounting bolts. Tool: 19 mm Torque: 35 N•m (3.5 kgf•m, 26 lbf•ft) M1JB-07-012...
Page 308 MAINTENANCE 18. Retighten swing bearing mounting bolts to upperstruc- ture. Tool: 50 mm Torque: 2200 N•m (220 kgf•m, 1620 lbf•ft) M17V-07-009 Retighten swing bearing mounting bolts to undercar- riage. Tool: 46 mm Torque: 1750 N•m (175 kgf•m, 1290 lbf•ft) M1J1-07-024 7-96...
Page 309 MAINTENANCE 19. Retighten travel device mounting bolts. Tool: 41 mm Torque: 1400 N•m (140 kgf•m, 1030 lbf•ft) Retighten travel motor mounting bolts. Tool: 27 mm Torque: 300 N•m (30 kgf•m, 220 lbf•ft) M17V-07-048 Retighten sprocket mounting bolts. Tool: 41 mm Torque: 1400 N•m (140 kgf•m, 1030 lbf•ft) M17V-07-019 20.
Page 310 MAINTENANCE 22. Retighten shoe mounting bolts. ● ZX850 , 870H Tool: 41 mm Torque: 2000 N•m (200 kgf•m, 1475 lbf•ft) ● ZX850LC , 870LCH Tool: 41 mm Torque: 2000 N•m (200 kgf•m, 1475 lbf•ft) M17V-07-051 23. Retighten track guard mounting bolts. ●...
Page 311 MAINTENANCE T-bolt clamp Tool: 11 mm Torque: 10 N•m (1.0 kgf•m, 7.4 lbf•ft) M1JB-07-006 26. Retighten counterweight mounting bolt. Tool: 65 mm Torque: 2800 N•m (280 kgf•m, 2065 lbf•ft) M17V-07-054 Tool: 36 mm Torque: 700 N•m (70 kgf•m, 520 lbf•ft) M162-07-070 27.
Page 312 MAINTENANCE 28. Retighten front pin-retaining bolts. Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft) M1JB-07-003 M17V-07-009 Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft) M17V-01-005 7-100...
Page 313 MAINTENANCE Retighten front pin-retaining nuts. Tool: 30 mm Torque: 400 N•m (40 kgf•m, 295 lbf•ft) M162-06-032 7-101...
Page 314: Check O-Rings In Bucket Joints
MAINTENANCE 10 Check O-rings in Bucket Joints --- daily O-rings (1) are provided on both ends of the bucket joint pins as illustrated to the right, to prevent soil from entering the bucket joints and retain the grease in the bucket joints. There- by, wear on the bucket joint parts such as the pins and the arm tip can be reduced.
Page 315: 11 Retighten Cylinder Head Bolt
MAINTENANCE 11 Retighten Cylinder Head Bolt --- As required See your authorized dealer. 12 Inspect and Adjust Valve Clearance --- every 1 000 hours See your authorized dealer. 13 Check Fuel Injection Timing --- As required See your authorized dealer. 14 Measure Engine Compression Pressure --- every 1 000 hours See your authorized dealer.
Page 316 MAINTENANCE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-104...
Page 317: Hydraulic Circuit And Electrical Circuit
Consult your authorized dealer if any trouble should occur. • The excavator is equipped with the “O. H. S” (Optimum Hy- draulic System) developed by Hitachi. The “O. H. S” features: Quick response of the actuators. Improved precise swinging.
Page 318: Main Circuit
HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT MAIN CIRCUIT Bucket Boom Boom Cylinder Cylinder Cylinder Cylinder Pilot Valve Pilot Shut-oﬀ Solenoid Valve Pilot Control Center Joint Valve Hydraulic Oil Tank Swing Motor Travel (L) Travel (R) Aux. Bucket Boom II Boom I Arm I Arm II Swing...
Page 319 HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 320: Electrical Circuit
HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT ELECTLICAL CIRCUIT ZAXIS850-3/850LC-3/870H-3/870LCH-3 ELECTRICAL DIAGRAM 1. GLOW RELAY 40. MONITOR 2. FUSIBLE LINK 41. NORMAL OPEN 3. BATTERY 42. BOOM MODE SWITCH 4. SAFETY RELAY 43. LEARNING SWITCH 5. PILOT SHUT-OFF SOLENOID VALVE 44. TRAVEL ALARM DEACTIVATION SWITCH 6.
Page 321: Electrical Diagram
ELECTRICAL DIAGRAM AUTO RE-FUELING (13) STARTER SWITCH OPTION BOX GROUND GLOW RELAY (61) FRESH AIR/CIRCULATION AIR AIR CONDITIONER UNIT CAB OUTSIDE CAB INSIDE SELECT SERVO MOTER (MRF) (60) FRONT VENT SERVO MOTER (MV2) FUSIBLE LINK (57) CAB INSIDE CAB OUTSIDE BLOWER MOTER BLOWER RESIST.
Page 322 HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 323: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or Before Operation: Check the tightness of plug and all drain cocks. Snowy Weather After Operation: Clean the machine and check for cracks, damaged, loose or missing bolts and nuts.
Page 324 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 325: Storing The Machine
Precautions for Disconnecting or Connecting Batteries In case the batteries are kept disconnected for more than one month or when the batteries are reconnected, contact your nearest Hitachi dealer. Resetting of the ICX (Information Controller) may be required. 10-1...
Page 326: Removing The Machine From Storage
STORAGE REMOVING THE MACHINE FROM STORAGE CAUTION: Start the engine ONLY in a well-ventilated place. 1. Remove grease from the cylinder rods if coated. 2. Adjust alternator and fan belt tension. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels.
Page 327: Troubleshooting
TROUBLESHOOTING ENGINE Problem Cause Solution Engine Cranks But Will Not No fuel Add fuel. Start or Hard to Start Bleed air. Wrong fuel Drain tank. Use correct fuel. Contaminated fuel Drain tank and add clean fuel. Low battery power Charge or install new battery. Injection pump See your authorized dealer.
Page 328 TROUBLESHOOTING ENGINE Problem Cause Solution Engine Not Developing Full Air filters plugged Replace filter elements. Power Fuel line restricted Repair or replace fuel line. Contaminated fuel Drain fuel tank and clean outlet screen. Refill. Fuel filters plugged Change filters. Plugged vent in fuel tank cap Clean or install new cap.
Page 329 TROUBLESHOOTING ENGINE Problem Cause Solution Coolant Temperature Too Low Thermostat See your authorized dealer. Temperature gauge or sending unit See your authorized dealer. Low Engine Oil Pressure Engine oil pump or pump drive See your authorized dealer. Low oil level Add oil.
Page 330 TROUBLESHOOTING ENGINE Problem Cause Solution Exhaust Gas is White Wrong fuel Drain tank. Use correct fuel. Cold engine Run engine until warm. Thermostat faulty or too “cool” See your authorized dealer. Injection pump out of time See your authorized dealer. Coolant leakage into engine cylinder See your authorized dealer.
Page 331: Electrical System
TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution Nothing Works Battery Recharge or replace. Nothing Works (Except clock) Battery relay Replace relay. Batteries Undercharged Loose or corroded connections Clean and tighten or replace batteries. Alternator belt loose Tighten or install new belt. Alternator not charging See your authorized dealer.
Page 332 TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution Engine Cranks Slowly Battery discharged or will not hold a Replace battery. charge Starter “dragging” See your authorized dealer. Low battery voltage Recharge or replace battery. Starter Motor Continues to Run Start relay stuck See your authorized dealer.
Page 333 TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution No Indicators in Gauge Panel Circuit board See your authorized dealer. Operate Wiring harness See your authorized dealer. Fuse Replace fuse. Indicator Light in Gauge Panel Bulb Replace bulb. is Inoperative Fuse Replace fuse. Sender Do sender check.
Page 334 TROUBLESHOOTING ELECTRICAL SYSTEM Problem Cause Solution Work Mode Selector Mode switches See your authorized dealer. Does Not Work Electrical connector See your authorized dealer. Wire harness (between MC and moni- See your authorized dealer. tor) Main controller (MC) See your authorized dealer. Solenoid valve unit See your authorized dealer.
Page 335: Control Levers
TROUBLESHOOTING CONTROL LEVERS Problem Cause Solution Moves Hard Worn out pusher See your authorized dealer. Pilot valve See your authorized dealer. Does Nothing Worn out pusher See your authorized dealer. Pilot valve See your authorized dealer. Does Not Return to Neutral Pilot valve See your authorized dealer.
Page 336 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution Hydraulic Oil Overheats Relief valve See your authorized dealer. Contaminated oil Drain oil and refill. Travel motors See your authorized dealer. Improperly adjusted hydraulic compo- See your authorized dealer. nents Oil Foams Air leak in line from reservoir to pump Repair leak or see your authorized deal- Check lines.
Page 337 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution One Control Lever Does Not Relief valve pressure low See your authorized dealer. Work Tube or hose damaged Repair or replace. Hydraulic fittings loose Tighten. Damaged O-rings in fittings Install new O-ring. Hydraulic Pump See your authorized dealer.
Page 338 TROUBLESHOOTING HYDRAULIC SYSTEM Problem Cause Solution Travel is Not Smooth Rocks or mud “jammed” in track frame Remove and repair. Travel brake not releasing See your authorized dealer. Swing Does Not Work Swing brake release valve See your authorized dealer. Swing motor See your authorized dealer.
Page 339: Specifications
SPECIFICATIONS SPECIFICATIONS (BACKHOE) ZAXIS850 , 850LC M1JB-12-001 Model ZAXIS850 ZAXIS850LC Type of Front-End Attachment 3.7 m (12 ft 2 in) Arm Bucket Capacity (Heaped) PCSA 3.4 m (4.45 yd ), CECE 3.0 m PCSA 3.5 m (4.58 yd ), CECE 3.1 m Operating Weight 80500 kg (177500 lb) 82200 kg (181200 lb)
Page 340 SPECIFICATIONS ZAXIS850 850LC M1JB-12-002 7.1 m Category 8.4 m (27 ft 7 in) Boom (23 ft 4 in) Item BE-Boom 3.7 m (12 ft 2 in) 4.4 m (14 ft 5 in) 2.95 m (9 ft 8 in) Semi-long Arm Be-Arm Backhoe Backhoe...
Page 341: Zaxis850 -3 , Zaxis850Lc -3
SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS850 Shoe Width mm (in) 650 mm (26") 750 mm (30") Grouser Shoe Grouser Shoe Application For Ordinary Ground (Standard) For Weak Footing (Option) Operating Weight 80500 81100 (lb) (177500) (178800) Base Machine Weight kg 60900 61600 (lb)
Page 342: Bucket Types And Applications (Backhoe)
SPECIFICATIONS BUCKET TYPES AND APPLICATIONS (BACKHOE) ZAXIS850 Bucket Capacity Bucket Width Front-End Attachment mm (in) m (ft•in) 7.1 m (23’4”) 8.4 m (27’ 7”) Weight Without Bucket With side BE-Boom Boom kg (Ib) PCSA CECE side cutter, (Heaped) (Heaped) cutter, 2.95 m (9'8") 3.7 m (12’2”) 4.4 m (9’8”)
Page 343: Specifications (Backhoe)
SPECIFICATIONS SPECIFICATIONS (BACKHOE) ZAXIS870H , 870LCH M1JB-12-003 Model ZAXIS870H ZAXIS870LCH Type of Front-End Attachment 3.7 m (12 ft 2 in) H Arm Bucket Capacity (Heaped) PCSA 3.4 m (4.45 yd ), CECE 3.0 m PCSA 3.5 m (4.58 yd ), CECE 3.1 m Operating Weight 82100 kg (181000 lb) 84000 kg (185200 lb)
Page 344: Working Ranges (Backhoe)
SPECIFICATIONS WORKING RANGES (BACKHOE) ZAXIS870H , 870LCH M1JB-12-004 Category 8.4 m (27 ft 7 in) H-Boom 7.1 m (23 ft 4 in) BE-Boom 3.7 m (12 ft 2 in) H-Arm 2.95 m (9 ft 8 in) BE-Arm 3.7 m (12 ft 2 in) H-Arm Backhoe Backhoe Backhoe...
Page 345: Shoe Types And Applications
SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZAXIS870H Shoe Width mm (in) 650 mm (26") 750 mm (30") Grouser Shoe Grouser Shoe Application For Ordinary Ground (Standard) For Weak Footing (Option) Operating Weight 82100 82800 (lb) (181000) (182500) Base Machine Weight kg 61600 62300 (lb)
Page 346: Bucket Types And Applications (Backhoe)
SPECIFICATIONS BUCKET TYPES AND APPLICATIONS (BACKHOE) ZAXIS870H Bucket Capacity Bucket Width Front-End Attachment mm (in) m (ft•in) 7.1 m (23’4”) 8.4 m (27’ 7”) Weight Without Bucket With side BE-Boom H-Boom kg (Ib) PCSA CECE side cutter, (Heaped) (Heaped) cutter, 2.95 m (9'8") 3.7 m (12’2”) 3.7 m (12’2”)
Page 347: Lifting Capacities
SPECIFICATIONS LIFTING CAPACITIES NOTE: 1. Lifting capacity of the ZX series does not exceed 75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. 2. * Indicates load limited by hydraulic capacity. M1G6-13-013 A: Rating over-side or 360 degrees B: Rating over-front...
Page 348 SPECIFICATIONS LIFTING CAPACITIES NOTE: 1. Lifting capacity of the ZX series does not exceed 75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. 2. * Indicates load limited by hydraulic capacity. M1G6-13-013 A: Rating over-side or 360 degrees B: Rating over-front...
Page 349: Sound Level Results (2000/14/Ec)
SPECIFICATIONS SOUND LEVEL RESULTS (2000/14/EC) LwA: sound-power level of airborne noise LpA: sound level at operator’s station Unit: dB(A) ZAXIS850 , 850LC 870H , 870LCH VIBRATION LEVEL Hands/Arms: The acceleration to which the operator's hands and arms will be exposed is lower than 2.5 m/s Entire body: The acceleration to which the operator's entire body will be exposed is lower than...
Page 350 SPECIFICATIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-12...
Page 351: Optional Attachments And Devices
OPTIONAL ATTACHMENTS AND DEVICES HYDRAULIC BREAKER Select a breaker that is the correct size and weight for your ma- chine. See your authorized dealer for correct breaker informa- tion. Carefully study the operation manuals of the machine and breaker, and perform the required checks and/or inspection Close Open before connecting the breaker to the arm.
Page 352: Work Mode
Select this mode switch when using NPK E-260B respectively. Flow Rate 350L/min) NOTE: The manufacturer of the hydraulic breaker may change the hydraulic breaker specifications without giving no- tice. Contact your nearest Hitachi dealer for any ques- tionable points. 13-2...
Page 353: Breaker Operation
OPTIONAL ATTACHMENTS AND DEVICES BREAKER OPERATION The breaker can be operated using attachment pedal (1) lo- cated on the right front of the seat, as illustrated. WARNING: Be sure to lock attachment pedal (1) with pedal lock (2) when the attachment pedal is not in use.
Page 354 OPTIONAL ATTACHMENTS AND DEVICES IMPORTANT: Turn the boom mode switch (3) [OFF] when operating a hydraulic breaker. If the boom mode switch (3) is turned [ON], boom-lower- ing force is reduced so that the designed hy- draulic breaker power cannot be sufficiently utilized.
Page 355: Precautions For Breaker Operation
OPTIONAL ATTACHMENTS AND DEVICES PRECAUTIONS FOR BREAKER OPERATION WRONG WARNING: Machine stability is reduced as the breaker is much heavier than the bucket. When using a breaker, the machine is more apt to tip over. Also, flying objects may hit the cab or other part of the machine.
Page 356 OPTIONAL ATTACHMENTS AND DEVICES • Do not operate the breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydrau- WRONG lic system components. M104-05-059 • Do not use breaker for lifting operation. The machine tip- WRONG ping over and/or breaker damage may result.
Page 357 OPTIONAL ATTACHMENTS AND DEVICES • Do not operate breaker with the arm positioned vertically. Excessive vibration to the arm cylinder will occur, causing oil leakage. M147-05-013 • Press the breaker so that the chisel (the axis) is positioned RIGHT WRONG and thrusted perpendicular to the object.
Page 358 OPTIONAL ATTACHMENTS AND DEVICES • Do not hit one place for longer than one minute. If the hydraulic breaker is allowed to hit one place for a If a material is too hard to be long time, oil pressure may increase and accumulator b r o k e n i n o n e m i n u t e , immediately change the damage may result.
Page 359: Breaker Maintenance
OPTIONAL ATTACHMENTS AND DEVICES BREAKER MAINTENANCE Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to deteriorate the hydraulic oil quickly. For this reason, hydraulic oil must be changed and the hydraulic oil tank filter must be replaced more often than the machine attached with a bucket.
Page 360 OPTIONAL ATTACHMENTS AND DEVICES Breaker hour meter (1) is located in the operator’s cab on the right control panel. This hour meter (1) operates when the breaker pedal is depressed. Obtain the average breaker opera- tion ratio according to the following formula. Average breaker operation ratio (%) = Breaker operation hours/Excavator operation hours = (Present breaker hour me- ter reading –...
Page 361: Replace Breaker Circuit Return Oil Filter
OPTIONAL ATTACHMENTS AND DEVICES REPLACE BREAKER CIRCUIT RETURN OIL FILTER WARNING: Hydraulic oil may be hot. Wait for oil to cool before starting work. 1. Park the machine on a level surface. Lower the breaker to the ground. 2. Leave the machine for a while after stopping operation. After the oil temperature is cooled, push air bleed valve (10) to bleed air from the hydraulic oil tank.
Page 362: Hydraulic Crusher
OPTIONAL ATTACHMENTS AND DEVICES HYDRAULIC CRUSHER Machine stability, applicable hydraulic oil pressure and oil quantity for crusher, etc. must be examined when selecting a crusher. Be sure to consult your authorized dealer when selecting a crusher. For operational instructions, refer to the crusher instruction manual.
Page 363: Stop Valve Operation
OPTIONAL ATTACHMENTS AND DEVICES STOP VALVE OPERATION Stop Valve 2 The stop valves are connected to pipes routed on the boom. Stop valves 2 illustrated to the right are provided in only the kit including the secondary relief valve. Secondary Relief Valve View A •...
Page 364: Three-Way-Valve Operation (Machines Equipped With The Piping Common To Hydraulic Breaker And Crusher Operation)
OPTIONAL ATTACHMENTS AND DEVICES THREE-WAY-VALVE OPERATION (Machines equipped with the piping common to hydraulic breaker and crusher operation) Breaker • Turn the three-way-valve to the position as shown in the upper right illustration when using a hydraulic breaker to allow the return oil to flow back to the line filter. •...
Page 365: Precautions For Crusher Operation
OPTIONAL ATTACHMENTS AND DEVICES PRECAUTIONS FOR CRUSHER OPERATION Prevent machine tipping over and damage to the front at- tachment. Observe the following precautions for crusher operation. WARNING: Machine stability is reduced as crusher is much heavier than bucket. When operating with a crusher, the machine is more apt to tip over.
Page 366 OPTIONAL ATTACHMENTS AND DEVICES • When operating the crusher up high with the boom fully raised, be careful of falling objects. WRONG M107-05-048 • When operating the crusher on a floor in a building, first confirm that the floor has sufficient strength to support WRONG the load caused by crushing, in addition to the machine weight.

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