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Hitachi ZAXIS 450LC-3 Operator's Manual

Hydraulic.
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PART NO.
EM1J3-NA1-2
450LC
650LC
850LC
Hydraulic Excavator
Serial No 020001 and up
-3
-3
-3

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   Related Manuals for Hitachi ZAXIS 450LC-3

   Summary of Contents for Hitachi ZAXIS 450LC-3

  • Page 1

    PART NO. EM1J3-NA1-2 450LC 650LC 850LC Hydraulic Excavator Serial No 020001 and up...

  • Page 2

    ������������ ������������������������������������������������������� ���������������������������������������������������� ������������������������������������������������������� ����������������������������������������������������� �������������������������������������������� ������������������������������������������������������� ������������������������������������������������������� ���������������������������������������������������� ������������������������������� ������������������������������������������������������ ������������������������������������������������������ ������������������������������������������������������ ����������������������������������������� ������������������������������������������������������� ����������������������������������������������������� �������������������������������������������������������� ��������������������������������������������������������� ����������������������������������������������������� �������������������������������������������������� ����������������������������������������������� ��������������������������������������������������� ����������������������������������������������������� �������������������������������������������������������� ����������������������������������������������������� ���������������������������� ������������ �������������������������������������������������������� ������������������������������������������������� ������������������������������������������������������� ��������������������������������������������������������� ���������������������������������������������������������� ���������� ������������������������������������������������������ ���������������������������������������������������������� � ���������������������������������������������������������� ����������������������������������������������������� ������� ����������������������������������������������������� �������������������������������������������...

  • Page 3

    INDEX MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE ASSEMBLING MAINTENANCE MAI N TENANCEUNDERSPECI A LENVI R ONMENTALCONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENTS AND DEVICES INDEX...

  • Page 5

    MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual 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 6

    MACHINE NUMBERS M17P-01-001 ZX650LC M17V-00-002 ZX850LC SWING MOTOR TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M16J-07-007 ZX450LC ZX650LC M1J7-07-005...

  • Page 7

    MACHINE NUMBERS M1JB-00-001 ZX850LC HYDRAULIC PUMP TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M1J1-001 ZX450LC M1J7-07-003 ZX650LC , 850LC...

  • Page 8

    MACHINE NUMBERS BOOM TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M111-12-005 ARM TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M17V-00-005 BUCKET TYPE AND SERIAL NUMBER TYPE: MFG. NO.: M116-12-004...

  • Page 9: Table Of Contents

    CONTENTS MACHINE NUMBERS Evacuating in Case of Fire ............S-27 Beware of Exhaust Fumes............S-27 Precautions for Welding and Grinding ......... S-27 SAFETY Avoid Heating Near Pressurized Fluid Lines ....... S-28 Recognize Safety Information ............S-1 Avoid Applying Heat to Lines Containing Understand Signal Words .............S-1 Flammable Fluids ..............

  • Page 10: Table Of Contents

    OPERATING THE MACHINE Installing Fire Extinguisher (Optional) ........1-61 Control Lever (ISO Pattern) ............5-1 Pilot Control Shut-off Lever ............1-62 Control Lever (HITACHI Pattern) ..........5-2 Engine Stop Switch ..............1-62 Control Lever (4 Way Multi Valve) (Optional) ......5-3 Fuse Box ...................1-63 Attachment Pedal (Hydraulic Breaker) (Optional) ....

  • Page 11: Table Of Contents

    CONTENTS Installing Boom ................6-9 Automatic/manual Lubrication--- If Equipped ...7-19 Connecting Hoses Between Boom Cylinder and Electric Grease Gun ...............7-23 Machine ..................6-10 Electric Grease Gun --- If Equipped .........7-31 Installing Boom Cylinder Rod ..........6-11 Lubricator --- If Equipped ...........7-33 Installing Arm ................6-12 Front Joint Pins (Backhoe) ..........7-37 Connecting Arm Cylinder Rod ..........6-13 Swing Bearing .................7-39...

  • Page 12: Table Of Contents

    CONTENTS Adjust the Bucket Linkage (Backhoe) ......7-102 ZX650LC (BACKHOE) ..............13-17 Remove the Travel Levers ..........7-103 ZX850LC (BACKHOE) ..............13-25 Check and Replace Seat Belt ...........7-103 ZX850LC ..................13-26 Check Windshield Washer Fluid Level ......7-104 INDEX ....................14-1 Check Track Sag ..............7-105 Clean Cab Floor ..............7-107 Retighten Cylinder Head Bolt..........7-108 Inspect and Adjust Valve Clearance ......7-108 Check Fuel Injection Timing ..........7-108...

  • Page 13: Recognize Safety Information

    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 14: Follow Safety Instructions

    Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble,...

  • Page 15: Wear Protective Clothing

    SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing SA-438 Wet weather gear Respirator or filter mask.

  • Page 16: 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 accident.

  • Page 17: Never Ride Attachment

    SAFETY NEVER RIDE ATTACHMENT • Never allow anyone to ride attachments or the load. This is an extremely dangerous practice. ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.

  • Page 18: 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 operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware.

  • Page 19: 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 20: Precautions For Operations

    SAFETY PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equipment 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 21: 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 falling and to prevent the ground, stockpiles, or banks from collapsing.

  • Page 22: Equipment Of Opg

    • In case the machine is operated in areas where the possibility of falling stones or debris exists, equip genuine Hitachi OPG guard. Contact your nearest Hitachi dealer for installation method of the OPG guard. Depending on the specifications applied to your machine, modification of the machine to meet ROPS standards will be possible.

  • Page 23: 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 24

    SAFETY • Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. •...

  • Page 25: 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 26: 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 27: Keep Person Clear From Working Area

    SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment 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 machine movement.

  • Page 28: Avoid Tipping

    SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE- --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 29: 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 30: Avoid Power Lines

    SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments 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 31: 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 striking any object.

  • Page 32: Transport Safely

    SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the machine to be transported.

  • Page 33: 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 34: 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 35: 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 ASSEMBLY. •...

  • Page 36: 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 37: 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 disconnecting hydraulic or other lines. •...

  • Page 38: 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 39: 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 position if there is time. • Use a fire extinguisher if there is time. •...

  • Page 40: Avoid Heating Near Pressurized Fluid Lines

    SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized 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 41: Beware Of Asbestos And Silicon Dust And Other Contamination

    • Keep bystanders out of the work site during operation. • Asbestos might 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 42: Handle Chemical Products Safely

    • Improperly disposing of waste can threaten the environment 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 43: Visibility From Operator's Seat

    SAFETY VISIBILITY FROM OPERATOR’S SEAT • The field of view from the operator’s seat on this machine is partially interrupted by the sections of the machine. • Operate the machine with the full understanding that some areas around the machine are out of sight. • The visibility based on ISO 5006 from the operator’s seat on this machine is as follows: 1 m-Vicinity Visibility...

  • Page 44: Safety Signs

    Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. ZX450LC ZX850LC...

  • Page 45

    SAFETY SIGNS SS-862 SS-863 SS-859 S-33...

  • Page 46

    SAFETY SIGNS SS3106039 SS3092349 SS-408 S-34...

  • Page 47

    SAFETY SIGNS SS3077560 SS-1022 When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Do not grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand. SS4371371 S-35...

  • Page 48

    SAFETY SIGNS SS-024 SS-710 SS3089713 S-36...

  • Page 49: 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 M1J1-01-001 NOTE: A right illustration is a typical model. There is a different part in other models.

  • Page 50: Getting On / Off The Machine

    GETTING ON / OFF THE MACHINE GETTING ON / OFF THE MACHINE ZX450LC 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 51

    GETTING ON / OFF THE MACHINE ZX650LC , ZX850LC 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 52: Cab Features

    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 53

    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 54: 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 displayed. When the key switch is turned to the ON position, the starting screen displays for about two seconds and the basic screen displays.

  • Page 55: Outline

    OPERATOR'S STATION OUTLINE 1- Work Mode Display 2- Auto-Idle Display 3- Auxiliary 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) 13- Fuel Rate Display 14- Clock 15- Back Monitor Selector (Optional)

  • Page 56

    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 57

    OPERATOR'S STATION • Auto-Idle Display (2) When selecting auto-idle from the switch panel, auto-idle display (2) is displayed. When the key is turned ON, the data blinks for 10 seconds. • Auto-Lubrication Display (4) (Optional) When selecting auto-lubrication from the switch panel, auto-lubrication display (4) is displayed.

  • Page 58: 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) located under keys on icon display area (24). M1J5-05-002 1-10...

  • Page 59: Hour Meter, Fuel Gauge, Back Monitor Selector

    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). M81U-01-058 Fuel Gauge The fuel amount in the fuel tank is indicated.

  • Page 60: Menu Key, Optional Function Key, Alarm Light

    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 operating these keys even though the menu key is not operated. M1U1-01-043 F1 : Work Mode Selection F2 : Auxiliary F3 : Mail (Optional) F4: Auto-Lubrication (Optional)

  • Page 61: Coolant Temperature Gauge, Operating Status Icon Display

    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 attachment (1) selected at the work mode selection screen and operation modes such as auto-idle system (2) and Auto-Lubrication (3) and preheat display (4), etc when these systems are activated.

  • Page 62: Password Input (optional)

    PASSWORD INPUT (OPTIONAL) IMPORTANT: When required to activate the TEN-key function (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 63: In Case Of Inputting An Incorrect Password

    OPERATOR'S STATION In Case of Inputting an Incorrect Password 1. If inputting an incorrect password, the message “Password is incorrect. ” displays by pushing the determination key. Password Input Screen T1V5-05-01-093 Delete Key Determination Key T1V5-05-01-002 2. Return to the password input screen, by pushing the back key.

  • Page 64

    OPERATOR'S STATION 3. If inputting an incorrect password three times, a screen displays informing that the security lock has been applied, 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. Security Lock Screen T1V5-05-01-005 4.

  • Page 65: Extending Password Duration Time

    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 66: 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 1-18...

  • Page 67

    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 1-19...

  • Page 68: Contents Of Alarms

    Stop operation. Run the engine at low idle to lower the coolant temperature. M178-01-036 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 is low. Immediately stop engine.

  • Page 69

    OPERATOR'S STATION • Fuel Sensor Error Display Fuel Sensor Error Coolant Temperature When the fuel sensor is faulty or if the harness between Sensor Error Display Display fuel sensor and monitor unit is broken, the fuel sensor error display is displayed on the fuel gauge. •...

  • Page 70: 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 M1J1-01-002 located under...

  • Page 71

    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 work mode selection key F1 after basic screen displays, or select from main menu.

  • Page 72

    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 Menu Key mode screen displays.

  • Page 73

    OPERATOR'S STATION Attachment Specification Screen ZX450LC Maximum Pump 2 Flow Rate Breaker 1 Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) M1J5-01-011 Maximum Pump 2 Flow Rate Breaker 2 Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) M1J5-01-012...

  • Page 74

    OPERATOR'S STATION ZX650LC Maximum Pump 2 Flow Rate Breaker 1 Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) T1J7-05-02-001E Maximum Pump 2 Flow Rate Breaker 2 Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) T1J7-05-02-002E Maximum Pump 2 Flow Rate...

  • Page 75

    OPERATOR'S STATION ZX850LC Breaker 1 Maximum Pump 2 Flow Rate Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) T1JB-05-02-002E Breaker 2 Maximum Pump 2 Flow Rate Maximum Engine Speed Flow Combining Switching Valve : OFF (Refer to the Work Mode of Chapter 5) T1JB-05-02-003E Breaker 3...

  • Page 76

    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 Menu Key keys 1 and 2...

  • Page 77: 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 operating conditions screen displays. 3.

  • Page 78: 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 .

  • Page 79

    OPERATOR'S STATION 4. Push key 6 , and the fuel rate display will be added to basic screen. Key 6 T1V5-05-01-119 M1J1-01-015 Fuel Rate 1-31...

  • Page 80

    OPERATOR'S STATION Fuel Rate No Display 1. When the basic screen displays, push the menu key and display main menu. Fuel Rate Menu Key Basic Screen M1J1-01-015 2. Select fuel rate display/No display from main menu by using keys 1 and 2 .

  • Page 81

    OPERATOR'S STATION 4. Push key 6 , and return to the basic screen. Key 6 T1V5-05-01-164 Basic Screen M1J1-01-002 1-33...

  • Page 82: Password Change (optional)

    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 and 2 .

  • Page 83

    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. 6. If inputting the password again, push the delete key. T1V5-05-01-130 A New Password Determination Key Delete Key...

  • Page 84

    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 Delete Key T1V5-05-01-133 9.

  • Page 85: 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 surrounding situation. Auto-Control: ON Image on the monitor unit when traveling is automatically switched to that of the back monitor.

  • Page 86

    OPERATOR'S STATION Auto-Control: OFF Set automatic switching function of images between monitor 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. Select back monitor settings from main menu by using keys 1 and 2 .

  • Page 87: 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 maintenance settings screen displays.

  • Page 88

    OPERATOR'S STATION Change Interval Settings IMPORTANT: Change interval can only be set when maintenance information display is set to 1. Select change interval by using keys 1 and 2 Key 1 2. Set time for change interval by using keys 3 and 4 3.

  • Page 89

    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 determination key. The value of remaining hours is reset to that of change interval. Previous change date/hour is updated with current date and time.

  • Page 90

    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 91

    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 according to a password on, the scheduled maintenance screen for the items whose change...

  • Page 92: Mail (optional)

    IMPORTANT: This function is available only to a machine equipped with a satellite terminal. When using the mail function, consult your nearest Hitachi dealer. 1. When the basic screen displays, push mail selection key F3 and display mail screen. 2. If pushing a relevant request key, mail information is sent to ICF.

  • Page 93

    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 1-45...

  • Page 94: 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 95

    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 96: 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 1-48...

  • Page 97: Engine Control Dial, Auto-idle Switch

    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 Auto-idle switch (2) sets the engine speed control mode to...

  • Page 98: 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 99: 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 instrument panel illumination will light. • 2 Position Work light (2) will light in addition. M178-01-015 •...

  • Page 100: 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 101: Switch Panel (optional Included)

    OPERATOR'S STATION SWITCH PANEL (Optional included) Armrest NOTE: • There are switches for the standard and option. Before using the switches on the switch panel, make sure what kind of optional devices are equipped. • Raise the armrest when you operate the switch. • Travel Alarm Deactivation Switch (Optional) (1) • Seat Heat Switch (Optional) (2) • Auxiliary (3) Switch Location • Boom Mode Switch (4) M1J1-03-001 • Engine Oil Level / Coolant Level Switch (5) Front •...

  • Page 102

    OPERATOR'S STATION Travel Alarm Deactivation Switch (Optional) The travel alarm buzzer sounds during travel operation. When push 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 103

    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 excavation. When turned OFF, the machine can be raised off the ground with the front attachment, allowing the machine to evacuate if the machine becomes stranded in a muddy area.

  • Page 104

    OPERATOR'S STATION Rotating Light Switch (Optional) When 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 105

    OPERATOR'S STATION FAN ROTATION DIRECTION CONTROL SYSTEM (Optional) The radiator, oil cooler and intercooler cores are cleaned by rotating the fan in reverse. 1. Return control lever (1) to neutral while running the engine. Pull pilot control shut-off lever (2) to the LOCK position as illustrated.

  • Page 106

    OPERATOR'S STATION IMPORTANT: • Do not operate the pilot control shut- off lever and/or the key switch while activating the fan rotation direction control system, damage to the operating equipment may result. • As soon as any abnormality or danger is detected, stop the engine.

  • Page 107: Key Switch, Horn 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 power, 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 108: Cigar Lighter

    30 seconds after pushing cigar lighter (2) in, pull out cigar lighter (2) manually. Then, consult the your nearest Hitachi dealer. 1. Turn key switch (1) to the ACC or ON position. 2. Press and release cigar lighter (2) knob.

  • Page 109: Cab Light, Installing Fire Extinguisher (optional)

    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 (2). M1J1-01-029 1-61...

  • Page 110: 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 111: Fuse Box

    OPERATOR'S STATION FUSE BOX Fuse Box 1 Fuse Box 2 Fuse Box1 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...

  • Page 112: 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 113: Auto Air Conditioner

    OPERATOR'S STATION AUTO AIR CONDITIONER 1- Control Panel 2- Front Vent 3- Rear Vent 4- Foot Vent 5- Defroster Vent 6- Blower OFF Switch 7- Blower Switch 8- Liquid-Crystal Display (LCD) 9- Temperature Control Switch 10- Mode Switch 11- AUTO Switch M1U1-01-025 12- Air Conditioner Switch 13- Fresh Air Mode Switch...

  • Page 114

    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 LCD (8) panel will disappear and the blower stops in both the auto and manual modes.

  • Page 115

    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 LCD (8) center.

  • Page 116

    Abnormal air mix damper Abnormal both re-circulation and fresh air damper Abnormal refrigerant pressure NOTE: In case more than one fault is detected, press either “ ” or “ ” mark on the temperature control switch button to change the fault code displayed on the LCD in order. Press blower OFF-switch (6) to complete the diagnosing function. If any trouble has been found through operating the diagnostic function, contact your nearest Hitachi dealer for repair. 1-68...

  • Page 117

    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 AUTO Indicator • AUTO Switch (11) Selects the air conditioner operation mode in either AUTO or MANUAL.

  • Page 118: Cab Heater Operation, Cooling 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 operation.) After selecting the foot vent mode by operating mode switch (10), set the desired temperature using temperature control switch (9).

  • Page 119: 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 120: 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 121: 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 M1G6-01-026 8- Time Set Switches Tuning Procedure •...

  • Page 122: 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 second until an electronic tone is heard. Now, the selected station is preset for the selected station preset.

  • Page 123: Cab Door Release Lever

    OPERATOR'S STATION CAB DOOR RELEASE LEVER CAUTION: • Open the cab door all the way until it securely locks in the latch on the side of the cab. • Do not keep the cab window open when the ma- chine is parked on a slope, or while the wind is blowing hard.

  • Page 124: Closing Upper Front Window

    OPERATOR'S STATION CLOSING UPPER FRONT WINDOW WARNING: Avoid possible injury while closing win- dow. 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 125: Removing And Storing Lower Front Window, Opening Side Windows

    OPERATOR'S STATION REMOVING AND STORING LOWER FRONT WINDOW WARNING: Take care not to pinch yours fingers when handling the lower front window. 1. Open the upper front window beforehand when removing the lower front window. 2. While pulling the lower front widow inward, raise it to remove.

  • Page 126: Opening/closing Overhead Window

    OPERATOR'S STATION OPENING/CLOSING OVERHEAD WINDOW Opening 1. Move locks (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 position by dampers (3). Closing 1.

  • Page 127: Emergency Exit

    OPERATOR'S STATION EMERGENCY EXIT Escape from the cab in emergency in the following methods: WARNING: The danger of downfall is always present when escaping from the cab in emergency, possibly resulting in serious personal injury. Escape from the cab as safely as possible, depending on the posture of machine and the outside situation.

  • Page 128: 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 adjusted independently, thus allowing the angle of the seat to be adjusted.

  • Page 129

    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 position by turning adjusting dial (6) located on the bottom of armrest (5).

  • Page 130: 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 adjusted independently, thus allowing the angle of the seat to be adjusted.

  • Page 131

    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 position by turning adjusting dial (6) located on the bottom of armrest (5).

  • Page 132: 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 adjusted independently, thus allowing the angle of the seat to be adjusted.

  • Page 133

    OPERATOR'S STATION Armrest Adjustment Armrest (6) can be pulled upright by hand to get on and off the machine easily. The angle of armrest (6) can be adjusted to the desired position by turning adjusting dial (7) located on the bottom of armrest (6).

  • Page 134: 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 using three 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 135: 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 136

    OPERATOR'S STATION MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-88...

  • Page 137: Observe Engine Operation Closely

    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 138

    BREAK-IN MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 139: Inspect Machine Daily Before Starting

    OPERATING THE ENGINE INSPECT MACHINE DAILY BEFORE STARTING ELECTRICAL SYSTEM Check for worn or frayed wires and loose connections. BOOM, BUCKET, SHEET METAL, TRACKS Check for bent, broken or missing parts. HARDWARE Check for loose or missing parts. FUEL SYSTEM Drain water and deposits from fuel tank.

  • Page 140: 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 141: Level Check

    OPERATING THE ENGINE LEVEL CHECK 1. Stop the 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 142

    Unless the TEN-key function (ignition block system) is activated, this screen is not displayed. IMPORTANT: When required to activate the TEN-key function (ignition block system), consult your nearest Hitachi dealer. Slow Idle M1U1-01-033 M178-01-049 Password Input Screen...

  • Page 143

    OPERATING THE ENGINE NOTE: When the maintenance information display is ON with the maintenance setting, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds. Then, the basic screen displays. 7. The basic screen will be displayed on the monitor. Check that preheat display (4) is OFF at this time. 8. Turn key switch (2) to start the engine. T1V5-05-01-170 IMPORTANT: Prevent the starter damage.

  • Page 144: Starting In Cold Weather

    Unless the TEN-key function (ignition block system) is activated, this screen is not displayed. IMPORTANT: When required to activate the TEN-key function (ignition block system), consult Slow Idle your nearest Hitachi dealer. M178-01-049 M1U1-01-033 Password Input Screen T1V5-05-01-002...

  • Page 145

    OPERATING THE ENGINE NOTE: When the maintenance information display is ON with the maintenance setting, the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds. Then, the basic screen displays. 7. The basic screen will be displayed on the monitor. The machine will automatically check if preheating is required or not. When preheating is required, preheat display (4) is lit for automatically. T1V5-05-01-170 NOTE: In case, preheat display (4) does not come ON, preheating is not required.

  • Page 146: Check Instruments After Starting

    OPERATING THE ENGINE CHECK INSTRUMENTS AFTER STARTING Checking the instruments through the Monitor Functions. After starting the engine, check the following points through the monitor functions. Check that 1. Alternator alarm (1) is off. 2. Engine oil pressure alarm (2) is off. 3.

  • Page 147: 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 148

    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 149: 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 150

    OPERATING THE ENGINE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 151: Drive The Machine Carefully

    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 152: Steering The Machine Using Pedals

    DRIVING THE MACHINE STEERING THE MACHINE USING PEDALS Front Idler WARNING: In the standard travel position, the front 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 actions of the travel pedals will be reversed.

  • Page 153: Steering The Machine Using Levers

    DRIVING THE MACHINE STEERING THE MACHINE USING LEVERS Front Idler WARNING: In the standard travel position, the front 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 actions of the travel levers will be reversed.

  • Page 154: 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 situation. Always stop the machine before changing the travel speed mode.

  • Page 155: 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 becomes stuck, it may be necessary to clean the track frame area.

  • Page 156: Towing Machine A Short Distance

    DRIVING THE MACHINE TOWING MACHINE A SHORT DISTANCE CAUTION: • Cables, straps, or ropes can break causing serious Soft Protector injury. Do not tow machine with damaged chains, frayed cables, slings, straps, or wire ropes. • Always wear gloves when handling cable, straps or wire ropes.

  • Page 157: 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 158: 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 159: Control Lever (iso Pattern)

    OPERATING THE MACHINE CONTROL LEVER (ISO PATTERN) WARNING: Never place any part of body beyond window 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 immediately.

  • Page 160: Control Lever (hitachi Pattern)

    OPERATING THE MACHINE CONTROL LEVER (HITACHI PATTERN) WARNING: Never place any part of body beyond window 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 immediately.

  • Page 161: Control Lever (4 Way Multi Valve) (optional)

    CONTROL LEVER (4 Way Multi Valve) (Optional) The control lever operation pattern is selected to one of four patterns, Y-type (ISO pattern), H-type (Hitachi pattern), M-type and K-type by shifting selector valve (1). WARNING: To prevent a serious accident or personal injury and/or death from occurring due to erratic machine movement, follow the instructions below.

  • Page 162: Attachment Pedal (hydraulic Breaker) (optional)

    OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC BREAKER) (Optional) The breaker can be operated using attachment pedal (1) located on the right front of the seat, as illustrated. WARNING: Using a hydraulic breaker in an improper breaker mode may cause the pump to supply excessive oil flow, possibly resulting in damage to the hydraulic components on the excavator and/or the hydraulic breaker.

  • Page 163

    OPERATING THE MACHINE WARNING: Be sure to lock attachment pedal (1) with pedal lock (2) when attachment pedal (1) is not in use. 1. Select the proper hydraulic breaker mode on work mode screen (6) depending on the necessary oil flow rate of hydraulic breaker employed.

  • Page 164

    OPERATING THE MACHINE ATTACHMENT PEDAL (HYDRAULIC CRUSHER) (Optional) 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 165

    OPERATING THE MACHINE PILOT CONTROL SHUT-OFF LEVER Pilot control shut-off lever (1) functions to prevent misoperation of the machine from occurring if the control levers are accidentally moved when leaving the operator's seat or when entering the cab. WARNING: • Always pull pilot control shut-off lever (1) into the full LOCK position.

  • Page 166: Warming-up Operation

    OPERATING THE MACHINE WARMING-UP OPERATION In cold weather, warm up the machine until coolant and hydraulic oil temperature increases to the appropriate operating temperature. Slow Idle IMPORTANT: The appropriate hydraulic oil operating temperature on this machine is 50 to 80°C. Hydraulic components may be seriously damaged if the machine is operated with M1U1-01-033...

  • Page 167: 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 engine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.

  • Page 168: Auto-idle

    OPERATING THE MACHINE AUTO-IDLE With auto-idle selector (3) turned to the A/I ON position, approximately 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 169: Work Mode

    2, 3 or 4 when the flow rate of the crusher corresponds to the breaker mode 1, 2, 3 or 4. NOTE: Five work modes shown above are designated as the standard specifications. Up to four attachment modes other than the digging mode can be designated. Consult your nearest Hitachi dealer for adding or changing the designation of the attachment modes. As for the machine equipped with the flow combined piping, when the flow combining valve is set to two pump combined, flow rate becomes the flow rate of selected breaker mode + pump 1.

  • Page 170: 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 171: Power Boost

    OPERATING THE MACHINE POWER BOOST Power boost switch (4) is used to gain maximum digging power, and is located on the top of the right control lever. When power boost switch (4) is pushed, increased front attachment power will be supplied for about 8 seconds. M1J1-01-024 5-13...

  • Page 172: 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 173: Operating Backhoe, Grading Operation

    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 174: 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 illustrated. 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 175: 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 attempt 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...

  • Page 176: Object Handling --- If Equipped

    OPERATING THE MACHINE OBJECT HANDLING --- IF EQUIPPED WARNING: When using machine for object handling operation, be sure to comply all local regulations. Lifting hook, cables, straps, or ropes can break, causing serious injury. Do not use damaged chains, lifting hook, frayed cables, slings, straps, or ropes to crane.

  • Page 177: Hydraulic Breaker And Hydraulic Crusher

    OPERATING THE MACHINE HYDRAULIC BREAKER AND HYDRAULIC CRUSHER Select a breaker or crusher that is the correct size and weight for your machine. See your authorized dealer for correct breaker information. Carefully study the operation manuals of the machine, Close Open breaker and crusher, and perform the required checks and/or inspection before connecting the breaker or the crusher to the...

  • Page 178: Stop Valve Operation

    OPERATING THE MACHINE 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 179: Flow Combining Valve Operation

    OPERATING THE MACHINE 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 180: Precautions For Breaker Operation

    OPERATING THE MACHINE 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 181

    OPERATING THE MACHINE • Do not operate the breaker in water. Doing so will cause rust and seal damage, resulting in damage to the WRONG hydraulic system components. M104-05-059 • Do not use breaker for lifting operation. The machine WRONG tipping over and/or breaker damage may result.

  • Page 182

    OPERATING THE MACHINE • Do not operate breaker with the arm positioned vertically. Excessive vibration to the arm cylinder will occur, causing WRONG oil leakage. M147-05-013 RIGHT WRONG • Press the breaker so that the chisel (the axis) is positioned and thrusted perpendicular to the object.

  • Page 183

    OPERATING THE MACHINE • Do not hit one place for longer than one minute. If a material is too hard to be If the hydraulic breaker is allowed to hit one place for a broken in one minute, long time, oil pressure may increase and accumulator immediately change the damage may result.

  • Page 184: Breaker Maintenance

    OPERATING THE MACHINE 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 and breaker-circuit oil filter must be replaced more often than the machine attached with a bucket.

  • Page 185

    OPERATING THE MACHINE 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 operation ratio according to the following formula. Average breaker operation ratio (%) = Breaker operation hours/Excavator operation hours = (Present breaker hour meter reading –...

  • Page 186: Replace Breaker Circuit Return Oil Filter

    OPERATING THE MACHINE REPLACE BREAKER CIRCUIT RETURN OIL FILTER WARNING: Hydraulic oil may be hot just after operation. Wait for oil to cool before starting work. 1. Park the machine on a level surface. Lower the breaker to the ground. 2.

  • Page 187: Precautions For Crusher Operation

    OPERATING THE MACHINE PRECAUTIONS FOR CRUSHER OPERATION Prevent machine tipping over and damage to the front attachment. 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 188

    OPERATING THE MACHINE • 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 WRONG confirm that the floor has sufficient strength to support the load caused by crushing, in addition to the machine weight.

  • Page 189: Attachment

    OPERATING THE MACHINE ATTACHMENT Allowable Weight Limits of Installed Attachment • When an attachment other than the standard bucket is installed on the machine, the machine stability will be different. If a heavy attachment is used, not only will controllability be affected but also machine stability will be reduced, possibly causing safety hazard.

  • Page 190

    OPERATING THE MACHINE Attachments Example commercial attachment models (breakers) for excavators are shown in the following table. When the machine is operated with an attachment other than bucket, generally heavier loads are applied to the base machine comparing with bucket only operation. Therefore, unless the machine is properly operated, damage not only the attachment but to the base machine may result.

  • Page 191

    OPERATING THE MACHINE Breaker (ZX650LC Maker Kounan Denki Okada Jackty Toukuu Model MKB3000V MKB4000V TOP300 TOP400 NJB240 TNB-230 TNB-310 TNB-400 Weight kg (lb) 3300 4200 2480 3250 3300 2453 3046 4326 (7280) (9260) (5470) (7160) (7280) (5410) (6720) (9540) Flow Rate (L/min) 170~260 220~300 160~215...

  • Page 192: 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 MACHINE” in the “DRIVING THE MACHINE” section. 2.

  • Page 193: Precautions For 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 194

    Be sure to use Hitachi original bolts. If the bolt length is too long or short, the bolt will not be tightened correctly,...

  • Page 195: 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 multiple number of signal persons are used, different signals may confuse the workers, possibly causing an accident).

  • Page 196: 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 machine, check that there are no bystanders or obstructions around the machine.

  • Page 197

    ASSEMBLING MACHINE LIFTING PROCEDURE (ZX450LC WARNING: • Lifting wire ropes and other lifting tools can break, possibly causing serious personal injury. Do not use damaged or deteriorated wire ropes or lifting tools. • Be sure to contact your authorized dealer for correct lifting procedure, and size and kinds of lifting wire ropes and lifting tools.

  • Page 198: Installing Counterweight

    ASSEMBLING INSTALLING COUNTERWEIGHT WARNING: Never allow anyone to enter into the area under the lifted counterweight. 1. Lift counterweight using a crane. 2. Insert the convex bosses of counterweight into the holes on base machine. 3. Apply a film of grease to two counterweight mounting bolts(10).

  • Page 199: Installing Boom Cylinder

    ASSEMBLING INSTALLING BOOM CYLINDER IMPORTANT: Take care not to mix up the right and left cylinders. Install the cylinder with the cylinder piping positioned downward. 1. Pull out boom cylinder bottom pins (2) until the end of the pin is flush with the inside end of the bracket. 2.

  • Page 200

    ASSEMBLING 10. Connect four hoses between both the right and left boom cylinders and the machine. Tightening torque: 180 N•m (18 kgf•m, 130 lbf•ft) 11. To prevent the seal from damage, bleed the air from the boom cylinder in the following procedures: (1) Run the engine at slow speed.

  • Page 201: Installing Boom

    ASSEMBLING INSTALLING BOOM Bracket WARNING: Never allow anyone to enter into the area under a lifted boom (2). 1. Pull out boom foot pin (1) until the end of the pin is flush with the inside end of the right side bracket. 2.

  • Page 202: 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 cylinder and the machine, gradually loosen bolts Frame securing the covers to the ends of the hydraulic...

  • Page 203: 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 boom cylinder (3) with that of boom (2) by moving boom cylinder (3) up and down while extending or retracting cylinder rod (1). WARNING: •...

  • Page 204: Installing Arm

    ASSEMBLING INSTALLING ARM WARNING: Never allow anyone to enter into the area under 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 205: Connecting Arm Cylinder Rod

    ASSEMBLING CONNECTING ARM CYLINDER ROD 1. To prevent seals from damage, bleed the air from arm cylinder (2) 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 206: 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 207: 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 section.) Bucket Boss 2. Start the engine. Raise arm (2) tip approximately 2.5 m M1J1-06-024 (2.7 yd) above the ground.

  • Page 208: Installing And Adjusting Mirror

    ASSEMBLING INSTALLING AND ADJUSTING MIRROR WARNING: Adjust the mirror position prior to operation. If the mirror is incorrectly positioned, sufficient eye-sight is not obtained, possibly creating a risk of any hazards resulting in personal injury. IMPORTANT: The side mirror shall be used as auxiliary equipment.

  • Page 209

    ASSEMBLING MACHINE LIFTING PROCEDURE (ZX650LC WARNING: • Lifting wire ropes and other lifting tools can break, possibly causing serious personal injury. Do not use damaged or deteriorated wire ropes or lifting tools. • Be sure to contact your authorized dealer for correct lifting procedure, and size and kinds of lifting wire ropes and lifting tools.

  • Page 210

    ASSEMBLING INSTALLING COUNTERWEIGHT WARNING: Never allow anyone to enter into the area under lifted counterweight (1). 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, 2030 lbf•ft) 3.

  • Page 211

    ASSEMBLING INSTALLING BOOM CYLINDER IMPORTANT: Take care not to mix up the right and left cylinders. Install the cylinder with the cylinder piping positioned downward. 1. Pull out boom foot pins (2) until the end of the pin is flush with the inside end of the bracket. 2.

  • Page 212

    ASSEMBLING 10. Connect four hoses between both the right and left boom cylinders and the machine. Tightening torque: 180 N•m (18 kgf•m, 130 lbf•ft) 11. To prevent the seal from damage, bleed the air from the boom cylinder in the following procedures: (1) Run the engine at slow speed.

  • Page 213

    ASSEMBLING INSTALLING BOOM Bracket WARNING: Never allow anyone to enter into the area under a lifted boom (2). 1. Pull out boom foot pin (1) until the end of the pin is flush with the inside end of the right side bracket. 2.

  • Page 214

    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 cylinder and the machine, gradually loosen bolts Frame securing the covers to the ends of the hydraulic...

  • Page 215

    ASSEMBLING INSTALLING BOOM CYLINDER ROD 1. Sling left-hand boom cylinder (3) with a crane. 2. Align the rod-pin bore of boom cylinder (3) with that of boom (2) by moving boom cylinder (3) up and down while extending or retracting cylinder rod (1). WARNING: •...

  • Page 216

    ASSEMBLING INSTALLING ARM WARNING: Never allow anyone to enter into the area under 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 217

    ASSEMBLING CONNECTING ARM CYLINDER ROD 1. To prevent seals from damage, bleed the air from arm cylinder (2) 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 218

    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 219

    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 section.) Bucket Boss 2. Start the engine. Raise arm (2) tip approximately 2.5 m M1J1-06-024 (2.7 yd) above the ground.

  • Page 220

    ASSEMBLING INSTALLING AND ADJUSTING MIRROR WARNING: Adjust the mirror position prior to opera- tion. If the mirror is incorrectly positioned, sufficient eye-sight is not obtained, possibly creating a risk of any hazards resulting in personal injury. IMPORTANT: The side mirror shall be used as auxiliary equipment.

  • Page 221

    ASSEMBLING MACHINE LIFTING PROCEDURE (ZX850LC WARNING: • Lifting wire ropes and other lifting tools can break, possibly causing serious personal injury. Do not use damaged or deteriorated wire ropes or lifting tools. • Be sure to contact your authorized dealer for cor- rect lifting procedure, and size and kinds of lifting wire ropes and lifting tools.

  • Page 222

    ASSEMBLING INSTALLING COUNTERWEIGHT WARNING: Never allow anyone to enter into the area under lifted counterweight (1). 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 223

    ASSEMBLING INSTALLING BOOM CYLINDER IMPORTANT: Take care not to mix up the right and left cylinders. Install the cylinder with the cylinder piping positioned downward. 1. Pull out boom foot pins (2) until the end of the pin is flush with the inside end of the bracket. 2.

  • Page 224

    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 procedure as taken in the steps 2 to 5 above. WARNING: •...

  • Page 225

    ASSEMBLING INSTALLING BOOM Bracket WARNING: Never allow anyone to enter into the area under a lifted boom (2). 1. Pull out boom foot pins (1) until the end of the pin is flush with the inside end of the right side bracket. 2.

  • Page 226

    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- Frame ing the covers to the ends of the hydraulic piping...

  • Page 227

    ASSEMBLING INSTALLING BOOM CYLINDER ROD 1. Sling left-hand boom cylinder (3) with a crane. 2. Align the rod-pin bore of boom cylinder (3) with that of boom (2) by moving boom cylinder (3) up and down while extending or retracting cylinder rod (1). WARNING: •...

  • Page 228

    ASSEMBLING INSTALLING ARM WARNING: Never allow anyone to enter into the area under 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 229

    ASSEMBLING CONNECTING ARM CYLINDER ROD 1. To prevent seals from damage, bleed the air from arm cylinder (2) 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 230

    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 231

    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 section.) Bucket Boss 2. Start the engine. Raise arm (2) tip approximately 2.5 m M1J1-06-024 (2.7 yd) above the ground.

  • Page 232

    ASSEMBLING INSTALLING AND ADJUSTING MIRROR WARNING: Adjust the mirror position prior to opera- tion. If the mirror is incorrectly positioned, sufficient eye-sight is not obtained, possibly creating a risk of any hazards resulting in personal injury. IMPORTANT: The side mirror shall be used as auxiliary equipment.

  • Page 233: Final Inspection

    (Refer to the page for “Check Hydraulic Oil Level” in the maintenance section.) 4. Check track sag. (Refer to the page for “Check Track Sag” in the maintenance section.) 5. Check that all equipment is correctly functioning. If any abnormality is found, contact your authorized Hitachi dealer. 6-41...

  • Page 234: Transporting By Road, Loading/unloading On A Trailer

    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 235

    TRANSPORTING Loading/Unloading WARNING: • Always turn the auto-idle 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 slow speed mode with the travel mode switch.

  • Page 236

    TRANSPORTING 4. Stop the engine. Remove the key from the key switch. 5. Move the control levers several times until hydraulic pressure 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 exhaust opening, to prevent entry of wind and water.

  • Page 237

    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 attachment. Always position the arm at 90° to the boom when unloading the machine. Unloading the machine with the arm tucked in may cause machine damage.

  • Page 238: Retracting Or Extending The Side Frame

    TRANSPORTING RETRACTING OR EXTENDING THE SIDE FRAME WARNING: • Thoroughly remove dirt or pebbles stuck to contact areas of the track frame and side frame. Otherwise, mounting bolts may be loosened. • Always extend the side frames when operating the excavator at job sites. Retraction of the side frames is designed only for easy transportation of the excavator by trailer.

  • Page 239: Retracting The Side Frame

    TRANSPORTING RETRACTING THE SIDE FRAME ZX450LC WARNING: Do not loosen side frame guide, bolts (2). WARNING: Remove and clean mud and gravel from contact 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 240

    TRANSPORTING ZX650LC 850LC WARNING: Do not loosen side frame guide bolts (2). IMPORTANT: Remove and clean mud and gravel from contact area of track frame (3) and side frame (4) using compressed air. Required Tools: Power Boost Wrench (including accessories) Torque Wrench (width across flats: 55 mm) Air Compressor (slide surface cleaning) 1.

  • Page 241: 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. • Lever Block (JIS B8819 equivalent to L3.2T) ....2 Used * Check that there is no damage on the lever block.

  • Page 242

    TRANSPORTING 4. Wind two wire ropes (4) around the front and rear sections (one wire rope on each section) of side frame (3). Connect lever blocks (5) to the ends of each wire rope. Attach soft protectors (6) between side frame (3) corners and wire ropes (4) to prevent damage to side frame (3) and wire ropes (4).

  • Page 243

    TRANSPORTING WARNING: Be sure to slowly operate the boom. If quickly operated, lever blocks (5) 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 track frame (2).

  • Page 244

    TRANSPORTING ZX450LC (BACKHOE) Packing Dimensions and Weights for Transportation - 1 Base Machine (Without front attachment, side frame, side steps and ladder.) Overrall Weight width mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 4640 2660 3070 16000 (15’ 3”) (8’ 9”) (10’...

  • Page 245

    TRANSPORTING Boom Width Weight Boom mm (ft•in) mm (ft•in) mm (ft•in) kg (lb) 6.3 m 6570 2110 1100 4450 BE Boom (21’7’’) (6’11’’) (3’7’’) (9810) 7.0 m 7330 1820 1110 4150 Boom (24’ 1”) (6’) (3’ 7”) (9150) 8.23 m 8510 1920 1100...

  • Page 246

    TRANSPORTING Counterweight 2960 mm (9’ 9”) Weight: 9150 kg (20200 lb) 710 mm Height: 1340 mm (4’ 5”) (28”) M1J1-06-015 Side Step (Front) 515 mm Weight: 44 kg (97 lb) (20”) Height: 150 mm (6”) 2340 mm (7’ 8”) Side Step (Rear) 515 mm Weight: 30 kg (66 lb) (20”)

  • Page 247

    TRANSPORTING Packing Dimensions and Weights for Transportation - 2 Base Machine Shoe Width Overal Width mm (ft•in) Weight mm (in) (Except track side step) kg (lb) 3490/3070 3490/**2990 5630 mm (18’ 6”) 28500 (11’ 5”/10’ 1”) (11’ 5”/9’ 10”) (24”) (62800) (Extended/Retracted) 3640/3140...

  • Page 248

    TRANSPORTING Counterweight 2960 mm (9’ 9”) Weight: 9150 kg (20200 lb) 710 mm Height: 1340 mm (4’ 5”) (28”) M1J1-06-015 Side Step (Front) 515 mm Weight: 44 kg (97 lb) (20”) Height: 150 mm (6”) 2340 mm (7’ 8”) Side Step (Rear) Weight: 30 kg (66 lb) 515 mm (20")

  • Page 249

    TRANSPORTING Packing Dimensions and Weights for Transportation - 3 Base Machine Shoe Overal Width mm (ft•in) Weight 9860 mm (32’ 4”) Width (Except track side step) kg (lb) mm (in) 3490/3070 3490/**2990 33300 (11’ 5”/10’ 1”) (11’ 5”/9’ 10”) 3420 (26”) (73400) (Extended/Retracted)

  • Page 250

    TRANSPORTING Counterweight 2960 mm (9’ 9”) Weight: 9150 kg (20200 lb) 710 mm Height: 1340 mm (4’ 5”) (28”) M1J1-06-015 Side Step (Front) 515 mm (20”) Weight: 44 kg (97 lb) Height: 150 mm ( 6”) 2340 mm (7’ 8”) Side Step (Rear) 515 mm Weight: 30 kg (66 lb)

  • Page 251

    TRANSPORTING Packing Dimensions and Weights for Transportation - 4 Base Machine WARNING: 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. mm (ft•in) mm (ft•in) 12000...

  • Page 252

    TRANSPORTING ZX650LC (BACKHOE) Types of Packings for Transportation <Type 2> <Type 1> Base Machine without Base Machine without Front Attachment and Front Attachment Side Frames Counterweight Two Side Frames Boom Counterweight Boom Bucket Two Boom Cylinders Bucket Four Hydraulic Hoses Two Boom Cylinders Two Side Steps Four Hydraulic Hoses...

  • Page 253

    TRANSPORTING Packing Dimensions and Weights for Transportation - 1 Base Machine (Without front attachment) mm (ft•in) mm (ft•in) 5060 (16’ 7”) 2720 (8’ 11”) Overall Weight Width kg (lb) mm (ft•in) M1J7-06-010 3470 (11’ 5”) 19900 (43900) NOTE: Steps on the track frame and the side hydraulic oil tank, hand rails on the upper buttery box, upper fuel tank, and the side hydraulic oil tank must be removed to comply with the overall width...

  • Page 254

    TRANSPORTING Boom Overall Boom Length Weight Width m (ft•in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 6.8 m 7140 2510 1390 6110 BE Boom (23’ 5”) (8’ 3”) (4’ 7”) (13500) 6.8 m 7140 2510 1390 6270 BER Boom (23’...

  • Page 255

    TRANSPORTING Boom Cylinder 2830 mm (9'3") Weight: 550 kg × 2 (1210 lb × 2) Height: 380 mm (15”) 550mm (21") M17V-06-026 Hose Weight: 7 kg × 2 (15 lb × 2) 1150 mm (3'9") 10 kg × 2 (22 lb × 2) 1150 mm (3'9") M17V-06-027 Side Step (Front)

  • Page 256

    TRANSPORTING Handrail on the Side Hydraulic Oil Tank Weight: 24 kg (53 lb) Height: 400 mm (16”) 760mm (30") 2020mm(6'8") M1J1-06-003 Handrail on the Fuel Tank Weight: 19 kg (42 lb) Height: 1040 mm (3’ 5”) 870mm (34") 850mm(33") M1J7-06-008 Handrail on the Battery Box (Upper) Weight: 14 kg (31 lb)

  • Page 257

    TRANSPORTING Packing Dimensions and Weights for Transportation - 2 Base Machine (Without front attachment) Shoe Width mm (in) mm (ft•in) mm (ft•in) 650 (26) 6100 (20’ 0”) 3630 (11’ 3”) 750 (30) 6100 (20’ 0”) 3630 (11’ 3”) 900 (35) 6100 (20’...

  • Page 258

    TRANSPORTING Boom Overall Boom Length Weight Width m (ft•in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 6.8 m 7140 2510 1390 6110 BE Boom (23’ 5”) (8’ 3”) (4’ 7”) (13500) 6.8 m 7140 2510 1390 6270 BER Boom (23’...

  • Page 259

    TRANSPORTING Boom Cylinder Weight: 550 kg × 2 (1210 lb × 2) 2830 mm (9'3") Height: 380 mm (15”) 550mm (21") M17V-06-026 Hose Weight: 7 kg × 2 (15 lb × 2) 1150 mm (3'9") 10 kg × 2 (22 lb × 2) 1150 mm (3'9") M17V-06-027 Side Step (Front)

  • Page 260

    TRANSPORTING Handrail on the Side Hydraulic Oil Tank Weight: 24 kg (53 lb) Height: 400 mm (16”) 760mm (30") 2020mm(6'8") M1J1-06-003 Handrail on the Fuel Tank Weight: 19 kg (42 lb) Height: 1040 mm (3’ 5”) 870mm (34") 850mm(33") M1J7-06-008 Handrail on the Battery Box (Upper) Weight: 14 kg (31 lb)

  • Page 261

    TRANSPORTING ZX850LC (BACKHOE) Types of Packings for Transportation <Type 2> <Type 1> Base Machine without Base Machine without Front Attachment and Front Attachment Side Frames Counterweight Two Side Frames Boom Counterweight Boom Bucket Two Boom Cylinders Bucket Four Hydraulic Hoses Two Boom Cylinders Three Side Steps Four Hydraulic Hoses...

  • Page 262

    TRANSPORTING Packing Dimensions and Weights for Transportation - 1 Base Machine (Without front attachment, side frame, steps on the hydraulic oil tank side and handrails on the right- hand frame, the fuel tank upper and lubricator upper.) mm (ft•in) mm (ft•in) 6040 (19’...

  • Page 263

    TRANSPORTING Counterweight Weight: 13300 kg (29300 lb) Height: 1620 mm (5’ 4”) (2’4”) 3360 mm (11’ 0”) M1JB-06-003 Boom Overall Weight Width mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 7.1 m 7490 2700 1450 7670 BE Boom (24’ 7”) (8’...

  • Page 264

    TRANSPORTING Bucket Bucket Capacity Overall Weight (PCSA Heaped) Width mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 2.9 (3.8) 2210 1910 1780 2700 (7’ 3”) (6’ 3”) (5’ 10”) (5950) 3.5 (4.6) 2210 1910 2040 2950 (7’ 3”) (6’ 3”) (6’...

  • Page 265

    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”) M162-06-014 570 mm (1’10”) Handrail on the right side of the Base Machine...

  • Page 266

    TRANSPORTING Packing Dimensions and Weights for Transportation - 2 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. Shoe Width mm (ft•in)

  • Page 267

    TRANSPORTING Boom Overall Weight Width mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 7.1 m 7490 2700 1450 7670 BE Boom (24’ 7”) (8’ 10”) (4’ 9”) (16900) 7.1 m 7490 2700 1450 7690 BER Boom (24’ 7”) (8’ 10”) (4’...

  • Page 268

    TRANSPORTING Boom Cylinder Weight: 850 kg × 2 (1870 lb × 2) 2890 mm (9’6”) Height: 400 mm (16”) 575 mm (1’11”) M17V-06-026 Hose 1540 mm (5’ 1”) Weight: 13 kg × 2 (29 lb × 2) 9 kg × 2 (20 lb × 2) 1540 mm (5’...

  • Page 269

    TRANSPORTING Handrail on the right side of the Base Machine 570 mm (1’10”) Weight: 5 kg (11 lb) Height: 160 mm (6.3”) 255 mm (10”) M1JB-06-013 Handrail on the Fuel Tank Weight: 23 kg (51 lb) Height: 670 mm (2’ 2”) 1020 mm (3' 4") 1050 mm (3’...

  • Page 270

    TRANSPORTING MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6-78...

  • Page 271: Correct Maintenance And Inspection Procedures

    If there is any problem with your machine, repair it before operating or contact your authorized dealer. IMPORTANT: • Use only recommended fuel and lubricants. • Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.

  • Page 272: Check The Hour Meter Regularly

    • Lubricate, make service checks and adjustments at intervals shown on periodic maintenance guide table. (See page 7-7) USE CORRECT FUELS AND LUBRICANTS IMPORTANT: Always use recommended fuels and lubricants. Failure to do so will result in machine damage and loss of Hitachi product warranty.

  • Page 273: Layout

    MAINTENANCE LAYOUT ZX450LC Arm Cylinder Boom Washer Tank Bucket Cylinder Swing Bearing Center Joint Battery Tool Box • Electric Grease Gun • Auto-Lubrication Device Link A Swing Device Link B Reservoir Boom Cylinder Fuel Tank Control Lever Control Valve Fuel Filter Radiator/Oil Cooler Side Cutter Inter Cooler/Fuel Cooler...

  • Page 274

    MAINTENANCE ZX650LC Arm Cylinder Boom Washer Tank Swing Bearing Bucket Cylinder Battery Center Joint Tool Box • Electric Grease Gun • Auto-Lubrication Device Swing Device Link B Fuel Filter Boom Cylinder Link A Fuel Tank Control Lever Control Valve Reservoir Radiator/Oil Cooler Inter Cooler/Fuel Cooler Tooth...

  • Page 275

    MAINTENANCE ZX850LC 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 Control Lever Radiator/Oil Cooler Inter Cooler/Fuel Cooler Side Cutter...

  • Page 276: 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, unless otherwise specified. 1. Park the machine on a level surface. M104-07-021 2. Lower the bucket to the ground. 3.

  • Page 277: Hood And Access Covers

    MAINTENANCE HOOD AND ACCESS COVERS Cover Handle ZX450LC 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 Catch personal injury.

  • Page 278

    MAINTENANCE ZX650LC Cover Handle 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 279

    MAINTENANCE ZX850LC 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 280: Periodic Replacement Of Parts

    MAINTENANCE PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, 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 281: Maintenance Guide

    NOTE: Grease the bucket joint pins, swing bearing, and swing gear only using a grease gun even if the auto-lubrication device is kept activated. B. ENGINE (See Page 7-41) Interval (hours) Parts Quantity 1000 2000 1. Engine oil Oil Level Check 2. Engine oil Change 57 L (15.1 US gal) 3. Engine oil Filter Replacement NOTE: H Change 250 operating hours, if the content of sulfer of fuel is 2000 ppm or more. Consult your nearest Hitachi dealer for the details. 7-11...

  • Page 282

    MAINTENANCE C. TRANSMISSION (See Page 7-44) Interval (hours) Parts Quantity 500 1000 2000 Oil Level Check 1. Pump ZX650LC Change 6.2 L (1.6 US gal) Transmission 850LC Clean Air Breather Oil Level Check 2. Swing ZX450LC 6.5 L × 2 (1.7 US gal × 2) Reduction ZX650LC 10.5 L ×...

  • Page 283

    4. Clean Oil Cooler Front Screen NOTE: H Shorten maintenance interval when the machine is operated in dusty areas. X When genuine Hitachi coolant is used, change every two years or 4000 operating hours, whichever comes first. IMPORTANT: Use fresh water or normal tap water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 60 %. 7-13...

  • Page 284

    MAINTENANCE H. AIR CONDITIONER (See Page 7-85) 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 285

    X1 Front Joint Pin and Swing Bearing X2 Swing Gear Recommended Engine Oil IMPORTANT: Use only genuine Hitachi engine oil as shown below or engine oil equivalent to DH-1 specified in JASO. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be...

  • Page 286

    Temp. (–4 to 113°F) (14 to 113°F) (–4 to 113°F) (14 to 113°F) (–4 to 113°F) (14 to 113°F) Manufacturer Hitachi Super EX 46HN Idemitsu Kosan Super Hydro 46 WRHU British Petroleum Bartran HV46 Caltex Oil Rando Oil HD46 Texaco INC.

  • Page 287: A. Greasing

    MAINTENANCE A. GREASING AUTOMATIC LUBRICATION --- IF EQUIPPED The automatic lubrication device uses grease-tank-attached electric pump (1) to automatically lubricate the greasing points on the front attachment at intervals. Turn auto lubrication switch (2) ON, then confirm that auto lubrication displays (4), (5) display on monitor (3).

  • Page 288

    MAINTENANCE Adding Grease Via Grease Fittings Using Grease Gun: Add grease into grease tank (6) via grease fitting (7) located on the top of the tank using a electric grease gun. Note that grease may not be able to added via grease fitting (7) in cold weather as grease becomes hard.

  • Page 289

    MAINTENANCE AUTOMATIC/MANUAL LUBRICATION --- IF EQUIPPED IMPORTANT: The auto-lubrication system is not applied to the bucket connection pins, swing bearing, swing gears, and track adjuster. Manually lubricate these systems. Auto-Lubrication IMPORTANT: • The system will not operate unless grease M16J-OP9-001 pump switch (1) and switch (10) are ON.

  • Page 290

    Even after the above checking is conducted, in case auto- lubrication alarm still stays ON, stop auto-lubrication and manually lubricate. Then, consult your nearest Hitachi dealer for further tracing to find the cause of the M1J1-01-032 problem. IMPORTANT: After completing lubrication, release the remaining pressure to protect the grease pump from being damaged.

  • Page 291

    MAINTENANCE Manual Lubrication Perform manual lubrication using a manual lubricator. Manually lubricate the bucket joint pins swing bearing, swing gears in addition use manual lubrication system when adjusting the track sag or in case the auto-lubrication system fails. IMPORTANT: The system will not operate unless grease pump switch (1) and switch (10) are ON, Check if grease pump switch (1) and switch (10) are ON in case the system does not...

  • Page 292

    MAINTENANCE 5. Turn lubrication mode switch (3) to the OFF Position. 6. Loosen check valve (7) or trigger the grease gun to release the remaining pressure from the pump unit and the hoses in the hose reel (The pressurized grease may be slightly discharged from check valve (7) drain port at this time.) M1J1-01-032...

  • Page 293: Electric Grease Gun

    MAINTENANCE ELECTRIC GREASE GUN ZX450LC CAUTION: The electric grease gun is not a water- proof type. Do not 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 294

    MAINTENANCE Part Name 1- Switch 2- Motor Unit 3- Nozzle (CPN-2) 4- Cap 5- Grease Cartridge 6- Oil Cylinder 7- Chain 8- Battery 9- Battery Charger 10- Code 11- Plug 12- Band 13- Bracket M16J-07-044 M1U1-07-112 M16J-07-043 7-24...

  • Page 295

    MAINTENANCE Charger Operation Charging the Battery Pack General Before using your electric grease gun for the first time, the battery pack should be charged for 12 hours. If the battery pack is installed in the electric grease gun, remove it by following instructions under Installing or Removing Battery Pack.

  • Page 296

    MAINTENANCE Normal Charging Make sure power circuit voltage is the same as that shown on the charger specification plate, Connect charger to power source. The first charge should be for 12 hours before use. Insert battery pack into charger. The red light should glow indicating the battery is charging.

  • Page 297

    MAINTENANCE IMPORTANT: • To reduce the risk of injury, chargers should only be used to charge attached battery pack. Other types of batteries may burst causing personal injury and damage. Do not charge attached battery packs with any other charger. •...

  • Page 298

    MAINTENANCE Preparation Install Cartridge Grease IMPORTANT: Take care not to allow soil and/or dust to become mixed into grease when installing grease cartridge (5). 1. Rotate to remove oil cylinder (6) from motor unit (2). 2. Pull chain (7) all the way out of oil cylinder (6) and hang the chain on the notch on the bottom groove of oil cylinder (6).

  • Page 299

    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 300

    MAINTENANCE After the battery charger is used IMPORTANT: Securely fasten the battery charger or the battery installed battery charger to the holding bracket with a band so that the battery charger does not come off the bracket. Failure to do so may cause the battery or battery charger to come off the holding bracket, possibly damaging the battery and/or battery charger.

  • Page 301: Electric Grease Gun --- If Equipped

    MAINTENANCE ELECTRIC GREASE GUN --- IF EQUIPPED ZX650LC , 850LC WARNING: The electric grease gun is not a water- proof type. Do not expose the grease gun to rain and water. Refrain from using the grease gun while raining. Failure to do so may cause unexpected trouble such as an electricity leak.

  • Page 302

    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 303: Lubricator --- If Equipped

    MAINTENANCE LUBRICATOR --- IF EQUIPPED ZX450LC Lubricator Operation 1. Turn power switch (8) ON to activate pump (1). Grease is sucked up and supplied to high-pressure grease gun (3). IMPORTANT: When pump (1) begins to suck grease, any air inside pump (1) will be mixed in, making grease turn whitish.

  • Page 304

    MAINTENANCE Grease Container Replacement When the grease container becomes empty, follow the procedure below to replace it. IMPORTANT: When replacing grease container (4), 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 pump (1) and to parts being lubricated will result.

  • Page 305

    MAINTENANCE ZX650LC , 850LC Lubricator Operation 1. Turn power switch (8) ON to activate pump (1). Grease is sucked up and supplied to high-pressure grease gun (3). IMPORTANT: When pump (1) begins to suck grease, any air inside pump (1) will be mixed in, making grease turn whitish.

  • Page 306

    MAINTENANCE Grease Container Replacement When the grease container becomes empty, follow the procedure below to replace it. IMPORTANT: When replacing grease container (4), 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 pump (1) and to parts being lubricated will result.

  • Page 307: Front Joint Pins (backhoe)

    MAINTENANCE Front Joint Pins (BACKHOE) Bucket and Link Pins --- every 10 hours Others --- every 50 hours (every 10 hours for first 100 hours) Vertical M1J1-07-057 This machine can be lubricated through grease fittings without using the auto lubrication device by following the procedure below.

  • Page 308

    MAINTENANCE • Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket Cylinder Bottom Pin. (When the auto lubrication device is not used) ZX450LC , 650LC M111-07-008 ZX850LC M162-07-006 • Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin. (Centralized greasing system) (When the auto lubrication device is not used) ZX450LC...

  • Page 309: 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 310: 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 311: B. Engine

    MAINTENANCE B. ENGINE 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. Reinsert dipstick (1).

  • Page 312: Change Engine Oil

    Change Engine Oil --- every 500 hours IMPORTANT: Change 250 operating hours, if the content of sulfer of fuel is 2000 ppm or more. Consult your nearest Hitachi dealer for the details. Replace Engine Oil Filter --- every 500 hours...

  • Page 313

    MAINTENANCE 14. Open the right access cover and secure the cover with rod. 15. Remove the filter cartridges of engine oil filter (6) by turning it counterclockwise with the filter wrench. 16. Clean the filter gasket contact area on the engine. 17.

  • Page 314: C. Transmission

    MAINTENANCE C. TRANSMISSION Pump Transmission Check Oil Level --- every 250 hours ZX650LC , 850LC 1. Park the machine on a level surface. M104-07-021 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

  • Page 315: 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. M104-07-021 IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

  • Page 316

    MAINTENANCE Change Gear Oil --- every 1000 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 engine is not properly shut down. 4.

  • Page 317: Travel Reduction Gear

    MAINTENANCE Air Release Plug 1 Travel Reduction Gear (Oil Supply Plug) Oil Level Check Check Oil Level --- every 250 hours Plug 2 1. Park the machine on a level surface. Horizontal Oil Level 2. Rotate the travel motor until the imaginary line through plug (1) and plug (3) is vertical.

  • Page 318

    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 319: D. Hydraulic System

    MAINTENANCE D. HYDRAULIC SYSTEM 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 inspection or maintenance.

  • Page 320

    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 321: 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 M104-07-021 retracted and the bucket cylinder fully extended. 3.

  • Page 322: Drain Hydraulic Oil Tank Sump

    MAINTENANCE Drain Hydraulic Oil Tank Sump --- every 250 hours WARNING: Hydraulic oil may be hot just after opera- tion. Be sure to wait for oil to cool before starting work. IMPORTANT: Never run the engine without oil in hydraulic oil tank. M1J1-07-006 1.

  • Page 323: Change Hydraulic Oil

    MAINTENANCE Change Hydraulic Oil Suction Filter Cleaning --- every 4000 hours, 2500 hours or 1500 hours WARNING: Hydraulic oil may be hot just after opera- tion. Wait for oil to cool before starting work. M104-07-117 IMPORTANT: Hydraulic oil changing intervals differ according to kind of hydraulic oils used.

  • Page 324

    MAINTENANCE 13. Remove suction filter and rod assembly (4). 14. Clean the filter and tank interior. If the filter is to be replaced, install new filter on the rod as shown. Tighten nut to 15 to 20 N•m (1.5 to 2.0 kgf•m, 10.5 to 14.5 lbf•ft). 15.

  • Page 325

    MAINTENANCE Air Bleeding Procedures Engine IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started. Bleed Air from Main Pump 1. Loosen plug (6) on the top of the main pump. Purge air from the main pump.

  • Page 326: Replace Hydraulic Oil Tank Filter

    MAINTENANCE Replace Hydraulic Oil Tank Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just after opera- tion. Be sure to wait for oil to cool before starting work. 1. Park the machine on a level surface. M104-07-021 2.

  • Page 327: Replace Pump Drain Filter

    MAINTENANCE Replace Pump Drain Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just after opera- tion. Be sure to wait for oil to cool before starting work. M104-07-021 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3.

  • Page 328: Zx850lc -3 M1jb

    MAINTENANCE Replace Pilot Oil Filter --- every 1000 hours WARNING: Hydraulic oil may be hot just after 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 329: Replace Air Breather Element

    MAINTENANCE 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 M104-07-021 starting work. Replacement Procedures 1.

  • Page 330: Check Hoses And Lines

    MAINTENANCE 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 331

    Exposed reinforcement (6) Replace Hose covers Blister (7) Replace M115-07-145 Hose Bend (8) Replace M115-07-146 Hose Collapse (9) Replace (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 7-61...

  • Page 332

    Crack (12) Replace on joints Clamps Missing Replace Deformation Replace Loose Retighten M137-07-007 NOTE: Refer to the illustrations in Fig.2 for each check point location or for a description of Fig.2 the abnormality. Use genuine Hitachi parts Table 3. Oil cooler Interval (hours) Check Points Abnormalities Remedies Every 250 hours Contact surfaces of Leak (14) Replace flange joints O-ring and/or...

  • Page 333: 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 leakage. 1. Inspect fitting sealing surfaces (6). They must be free of dirt or defects.

  • Page 334

    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.

  • Page 335: E. Fuel System

    MAINTENANCE E. FUEL SYSTEM Recommended Fuel Use high quality DIESEL FUEL only (JIS K-2204) (ASTM 2-D). Kerosene must NOT be used. Refueling 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 M1J1-01-007 engine is not properly shut down.

  • Page 336: Drain Fuel Tank Sump

    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. Model Tank Capacity ZX450LC 725 L (192 US gal) ZX650LC 900 L (238 US gal) ZX850LC 1120 L (296 US gal) ZX450LC...

  • Page 337: Drain Fuel Filter

    MAINTENANCE Drain Fuel Filter --- daily (Before staring operation) IMPORTANT: The engine may be damaged if you do not drain fuel filter daily. Fuel main filter and pre-filter separates that may mixed with the fuel. Fuel filter contains a float which rises as water accumulates. Be sure to drain daily the water accumulated in the filter until the float goes to the bottom of case.

  • Page 338

    MAINTENANCE Draining Procedures (Pre-Filter) Pre-Filter 1. Place 0.5 liters (0.5 US qt) or larger capacity container under drain plug (5) to collect the drained water. 2. Loosen plug (4) on the top of the fuel pre-filter. 3. Rotate drain plug (5) on the bottom of the pre-filter counterclockwise.

  • Page 339: Air Bleeding Procedures

    MAINTENANCE Air Bleeding Procedures 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 fuel filter, replacing the fuel filter or running the fuel tank dry, be sure to bleed the air from the fuel system.

  • Page 340: Replace Fuel Main Filter Element

    Replace Fuel Main Filter Element --- every 500 hours ZX450LC , 850LC IMPORTANT: Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.

  • Page 341

    MAINTENANCE ZX650LC IMPORTANT: Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers’...

  • Page 342: Replace Fuel Pre-filter Element

    Replace Fuel Pre-filter Element --- every 500 hours ZX450LC , 850LC IMPORTANT: Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.

  • Page 343

    MAINTENANCE ZX650LC IMPORTANT: Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers’...

  • Page 344: Check Fuel Hoses

    Crack (3) Replace hose Hose ends Crack (4) Replace M137-07-003 Hose Bend (5) Replace M137-07-004 Hose Collapse (6) Replace (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 7-74...

  • Page 345: F. Air Cleaner

    MAINTENANCE F. AIR CLEANER ZX450LC , 650LC 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.

  • Page 346

    MAINTENANCE 16. When replacing the air cleaner filter element, replace both outer and inner elements (3), (5) together. Slowly remove inner element (5) after removing outer element (3). Clean body (7) before installing new elements. First, install inner element (5) and then install outer element (3).

  • Page 347

    MAINTENANCE ZX850LC 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 348: G. Cooling System

    MAINTENANCE G. COOLING SYSTEM Coolant Fill the radiator with soft, pure tap or bottled water. Anti-rust agent Add approximately 0.8 L (0.8 US qt) of anti-rust agent to the new coolant when the coolant is changed. It is not necessary to add anti-rust agent when antifreeze is used.

  • Page 349

    MAINTENANCE Antifreeze Mixing Table(ZX450LC Refill capacities Mixing Air temperature ratio Antifreezes Soft water °C °F liters US gal liters US gal –1 16.5 38.5 10.2 –15 19.3 35.7 –20 –4 22.0 33.0 –25 –13 24.8 30.2 –30 –22 27.5 27.5 –50 –58 33.0...

  • Page 350: Check Coolant Level

    MAINTENANCE Radiator Upper Cover Check Coolant Level --- daily WARNING: Do not loosen radiator filler cap (1) unless the system is cool. Loosen cap (1) slowly to the stop. Release all pressure before removing cap (1). With the engine cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2), located side of the fuel tank.

  • Page 351: Change Coolant

    MAINTENANCE 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, the service intervals between changing the coolant is once every two years, or every 4000 hours, whichever comes first. SA-039 WARNING: Do not loosen the radiator cap until the system is cool. Loosen the cap slowly to the stop.

  • Page 352

    MAINTENANCE 2. Remove the radiator cap. Open drain cocks (1) and (2) on the radiator and engine block to allow the coolant to drain completely. 3. Close drain cocks (1) and (2). Fill the radiator with tap water and a radiator cleaner agent. Start the engine and run at a speed slightly higher than slow idle;...

  • Page 353: Clean Radiator/ Oil Cooler/ Inter Cooler Fuel Cooler Core

    MAINTENANCE Inter Cooler Clean Radiator/ Oil Cooler/ Inter Cooler/ Fuel Cooler Core --- every 500 hours 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.

  • Page 354: Clean Oil Cooler Front Screen

    MAINTENANCE Clean Oil Cooler Front Screen --- every 500 hours IMPORTANT: When operating the machine in a dusty environment, check the screen every day for dirt and clogging. If clogged, remove, clean and reinstall the screen. Screen M1J1-07-033 ZX450LC Screen M1J7-07-027 ZX650LC Screen...

  • Page 355: H. Air Conditioner

    MAINTENANCE H. AIR CONDITIONER 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 M1U1-07-010 1.

  • Page 356

    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 fresh air and circulating air filters by blowing compressed air or washing with water.

  • Page 357: Check Refrigerant (gas) Quantity

    MAINTENANCE 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 358: Check Compressor Belt Tension

    MAINTENANCE Check Compressor Belt Tension Idle Pulley Push Deflection --- every 250 hours (about 98N, 10kgf) 6 to 10 mm (0.24 to 0.39 in) Visually check belt for wear. Replace if necessary. Check belt tension by depressing the midpoint between the crank and idle pulleys with the thumb.

  • Page 359: Check Looseness At Each Of Fastened Areas

    MAINTENANCE Check Looseness at Each of Fastened Areas --- every 250 hours Check tightness of mounting bolts, hose connections and fittings after first 50 hours then every 250 hours. Tighten to torque specifications if any are loose. Torque Specifications for Hose Connections: Tightening Torque Wrench Size (mm)

  • Page 360: Check In-season And Off-season

    MAINTENANCE Check In-Season and Off-Season Preseason --- once a year, Off-season --- once a week WARNING: Do not attempt to loosen connections in air conditioning circuit when the air conditioner malfunctions. Doing so may cause high pressure gas to spout, resulting in serious injury. Consult your authorized dealer immediately.

  • Page 361: I. Electrical System

    MAINTENANCE I. ELECTRICAL SYSTEM WARNING: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment effects the machine's electronic parts, causing involuntary movement of the machine. Also, improper installation of electrical equipments may cause machine failure and/or a fire on the machine.

  • Page 362: Batteries

    MAINTENANCE Batteries --- every month 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 363

    MAINTENANCE If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable 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 364

    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 365

    MAINTENANCE Check electrolyte specific gravity --- every one month 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.

  • Page 366: Replacing Fuses

    MAINTENANCE Replacing Fuses --- as required If any electrical equipment fails to operate, first check the fuses. Fuse box is located behind the operator’s seat. A fuse Fuse Box 1 Fuse Box 2 location/specification decal is attached to the fuse box cover. Remove the fuse box cover by lifting it upward.

  • Page 367

    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 right side cover to check the fuse.

  • Page 368: J. Miscellaneous

    MAINTENANCE J. MISCELLANEOUS Check Bucket Teeth --- daily Check the bucket teeth for wear and looseness Check for wearing and looseness of the Bucket tooth points. 1. Replacement intervals Replace tooth point (1) wear beyond the service limit, replace them. Dimension A in mm (in) M1J1-07-065 Limit of...

  • Page 369

    MAINTENANCE (c) Removing the tooth point Turn tooth point (1) to the left, twist and pull it toward you to remove it. Remove the plug, and check if rubber has cracking; if it has, replace the rubber with new one. While the pin and plug can withstand several replacements of tooth point (1), be sure to check whether they are usable or not when replacing...

  • Page 370

    MAINTENANCE (b) Inserting the lock pin Insert lock pin (3) facing toward adapter (2) nose. With tooth point (1) fully inserted onto adapter (2), tap lock pin (3) into tooth point (1) with a hammer until the top of lock pin (3) comes flat with the nose surface.

  • Page 371: Change Bucket

    MAINTENANCE Change Bucket --- as required 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 372

    MAINTENANCE Adjust the Bucket Linkage (Backhoe) --- as required When play in the linkage increases, remove and install shims as follows: Clearance Adjust Part 1. Park the machine on a level surface. Lower the bucket to the ground with the flat side down so that the bucket will not roll.

  • Page 373

    MAINTENANCE Remove the Travel Levers --- as required 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 374: Check Windshield Washer Fluid Level

    MAINTENANCE Check Windshield Washer Fluid Level --- as required Windshield washer fluid tank (1) is located in the cover after the cab. Check windshield washer fluid tank (1) at daily. If the windshield washer fluid is needed, remove rubber cap (3)/cap (2) and add the windshield washer fluid.

  • Page 375

    MAINTENANCE 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 376

    MAINTENANCE Loosen the Track WARNING: Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting 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 377: Clean Cab Floor

    MAINTENANCE Clean Cab Floor --- as required 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 378: Retighten Cylinder Head Bolt

    MAINTENANCE Retighten Cylinder Head Bolt --- As required See your authorized dealer. Inspect and Adjust Valve Clearance --- every 1000 hours See your authorized dealer. Check Fuel Injection Timing --- As required See your authorized dealer. Measure Engine Compression Pressure --- every 1000 hours See your authorized dealer.

  • Page 379: Check Tightening Torque Of Bolts And Nuts

    MAINTENANCE 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 380

    MAINTENANCE Bolt Dia Torque Wrench Descriptions Q’ty LOCTITE Size (mm) N•m (kgf•m)) (lbf•ft) 22 Lower roller mounting bolt (75) (550) 23 Track shoe bolt 1370 (137) (1010) Standard (75) (550) Track guard mounting bolt Full-length (75) (550) 25 Track mounting bolt 1750 (175) (1290)

  • Page 381

    MAINTENANCE 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 382

    MAINTENANCE Bolt Dia Torque Wrench Descriptions Q’ty LOCTITE Size (mm) N•m (kgf•m) (lbf•ft) 22 Lower roller mounting bolt (95) (700) 23 Track shoe bolt 2000 (200) (1475) 1400 (140) (1035) Standard 24 Track guard mounting bolt Full-length 1400 (140) (1035) 25 Track mounting bolt 2800 (280)

  • Page 383

    MAINTENANCE 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 384

    MAINTENANCE Bolt Dia Torque Wrench Descriptions Q’ty LOCTITE Size (mm) N•m (kgf•m) (lbf•ft) 22 Lower roller mounting bolt (95) (700) 23 Track shoe bolt 2000 (200) (1475) 24 Track guard mounting bolt 1400 (140) (1030) 25 Track mounting bolt 2800 (280) (2065) Coupling...

  • Page 385

    MAINTENANCE Tightening Torque Chart Wrench Hexagon Bolt Dia. Size Wrench Size M552-07-091 M552-07-090 M157-07-225 Socket Bol N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) N•m (kgf•m) (lbf•ft) (3.0) (22) (2.0) (15.0) (1.0) (7.4) (6.5) (48) (5.0) (37) (2.0) (15.0) (11) (81) (9.0) (66) (3.5) (26.0)

  • Page 386

    MAINTENANCE 1. Retighten engine cushion rubber mounting bolts. Mounting Bolts (Fan side) ZX450LC , 650LC M1J1-07-022 Mounting Bolts (Pump side) (Engine − Cushion rubber) ZX850LC M1JB-07-020 (Machine − Cushion rubber) ZX450LC M1J1-07-040 ZX450LC ZX650LC , 850LC M1J1-07-043 M1JB-07-019 7-116...

  • Page 387

    MAINTENANCE 2. Retighten engine bracket mounting bolts. M1JB-07-020 ZX850LC (Fan side) ZX450LC , 650LC (Fan side) M1J1-07-046 M1JB-07-019 ZX650LC , 850LC (Pump side) 3. Retighten radiator mounting bolts. M1J7-07-018 ZX650LC M1J1-07-021 ZX450LC ZX850LC M1JB-07-011 7-117...

  • Page 388

    MAINTENANCE 4. Retighten oil cooler mounting bolts. M1JB-07-021 ZX850LC 5. Retighten hydraulic oil tank mounting bolts. M111-07-069 ZX450LC M1J7-07-012 ZX650LC M1JB-07-021 ZX850LC 7-118...

  • Page 389

    MAINTENANCE 6. Retighten fuel tank mounting bolts. M111-07-069 ZX450LC M1J7-07-021 ZX650LC M1JB-07-021 ZX850LC 7-119...

  • Page 390

    MAINTENANCE 7. Retighten ORS fittings for hydraulic hoses and piping. M110-07-048 ZX450LC M1JB-07-004 ZX850LC M1J7-07-029 ZX850LC ZX650LC M162-07-067 M1J7-07-05 ZX650LC 7-120...

  • Page 391

    MAINTENANCE 8. Retighten pump transmission mounting bolts. ZX650LC , 850LC M1JB-07-005 9. Retighten pump device mounting bolts. M1J1-07-023 ZX650LC , 850LC M1JB-07-005 ZX450LC 10. Retighten fan pump mounting bolts. M1JB-07-054 M1J1-001 ZX650LC , 850LC ZX450LC 7-121...

  • Page 392

    MAINTENANCE 11. Retighten fan motor mounting belts. M1JB-07-053 M1J7-07-047 ZX450LC , 850LC ZX650LC 12. Retighten control valve mounting bolts. M1J7-07-016 M1J1-07-020 ZX450LC ZX650LC ZX850LC M1JB-07-016 7-122...

  • Page 393

    MAINTENANCE 13. Retighten control valve bracket mounting bolts. ZX650LC M1J7-07-041 M1J1-07-052 ZX450LC M1JB-07-045 ZX850LC 14. Retighten swing device mounting bolts. M1J7-07-005 ZX650LC M1J1-07-001 ZX450LC M1JB-00-001 ZX850LC 7-123...

  • Page 394

    MAINTENANCE Retighten ring gear housing mounting bolt. M1J7-07-005 ZX650LC 15. Retighten swing motor mounting bolts. M1J1-07-001 M1J7-07-005 ZX450LC ZX650LC M1JB-00-001 ZX850LC 7-124...

  • Page 395

    MAINTENANCE 16. Retighten battery mounting nuts. M1J7-07-026 ZX650LC ZX450LC M1J1-07-014 ZX850LC M1JB-07-012 17. Retighten cab mounting nuts. M1U1-07-026 18. Retighten cab anchor mounting bolts. M1U1-07-054 ZX450LC 7-125...

  • Page 396

    MAINTENANCE 19. Retighten swing bearing mounting bolts to upperstructure. M17P-07-028 ZX650LC ZX450LC M166-07-013 M17V-07-009 ZX850LC Retighten swing bearing mounting bolts to undercarriage. M1J1-07-024 ZX850LC 7-126...

  • Page 397

    MAINTENANCE 20. Retighten travel device mounting bolts. Retighten travel motor mounting bolts. ZX650LC M17P-01-001 ZX450LC M1J1-07-048 Retighten sprocket mounting bolts. M17V-07-048 ZX850LC M111-07-078 M17P-07-011 ZX450LC ZX650LC M17V-07-019 ZX850LC 7-127...

  • Page 398

    MAINTENANCE 21. Retighten upper roller mounting bolts. ZX650LC M17P-07-031 M1J1-07-026 ZX450LC M17V-07-049 ZX850LC 22. Retighten lower roller mounting bolts. M17P-07-032 ZX650LC M107-07-092 ZX450LC M17V-07-050 ZX850LC 7-128...

  • Page 399

    MAINTENANCE 23. Retighten track shoe bolts. M17V-07-051 ZX650LC , 850LC M107-07-093 ZX450LC 24. Retighten track guard mounting bolts. ZX450LC M1J1-07-025 M17P-07-032 ZX650LC ZX850LC M17V-07-050 7-129...

  • Page 400

    MAINTENANCE 25. Retighten track mounting bolts. ZX650LC M17P-07-034 ZX450LC M111-07-079 ZX850LC M17V-07-052 26. Retighten coupling and clamp Coupling M1G6-07-008 ZX450LC , 650LC M1JB-07-030 ZX850LC 7-130...

  • Page 401

    MAINTENANCE T-bolt clamp ZX650LC M1J7-07-003 M1J1-07-037 ZX450LC M1JB-07-006 ZX850LC 27. Retighten counterweight mounting bolts. ZX650LC M1J7-07-023 ZX450LC M1J1-07-036 ZX850LC M17V-07-054 7-131...

  • Page 402

    MAINTENANCE Counterweight mounting retaining bolts. M162-07-070 28. Retighten shuttle valve mounting bolts. ZX450LC , 850LC M1J1-07-030 ZX650LC M1J7-07-009 7-132...

  • Page 403

    MAINTENANCE 29. Retighten front pin-retaining bolts. M111-07-083 ZX450LC M1J1-07-017 ZX450LC M111-07-084 ZX450LC M1J7-07-011 M17P-07-039 ZX650LC ZX650LC ZX850LC ZX850LC M1JB-07-003 M17V-07-009 7-133...

  • Page 404

    MAINTENANCE ZX450LC ZX650LC , 850LC M111-07-085 M17V-01-005 Retighten front pin-retaining nuts. M162-06-032 M111-07-086 ZX650LC , 850LC 30. Retighten fan mounting bolts. Retighten fan drive coupling mounting nut. ZX450LC , 850LC ZX650LC M1J1-07-080 M1J7-07-049 7-134...

  • Page 405

    MAINTENANCE 31. Retighten pilot pump mounting bolts. M1JB-07-054 ZX650LC , 850LC M1J1-07-081 ZX450LC 32. Retighten side branch piping bracket mounting bolts. M1J1-07-082 ZX450LC M1J7-07-050 ZX650LC ZX850LC M1JB-07-059 7-135...

  • Page 406

    MAINTENANCE 33. Retighten air compressor mounting bolts. M1J1-07-083 7-136...

  • Page 407: Check O-rings In Bucket Joints

    MAINTENANCE 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. Thereby, wear on the bucket joint parts such as the pins and the arm tip can be reduced.

  • Page 408

    MAINTENANCE MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-138...

  • Page 409: Environmental Conditions 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 410

    MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 411: 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 412: 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 413: Impossible To Start The Engine

    TROUBLESHOOTING IMPOSSIBLE TO START THE ENGINE Problem Cause Solution Starter does not rotate or is Discharged battery Charge or replace battery. not powerful Disconnected, loose, or corroded battery After repairing the corroded terminals area, securely tighten the connectors. Lowered pilot control shut-off lever. Pull pilot control shut-off lever up.

  • Page 414: Engine

    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 415: Troubleshooting

    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 416

    TROUBLESHOOTING ENGINE Problem Cause Solution Nothing Works Battery Recharge or replace. Nothing Works Battery relay Replace relay. (Except clock) 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 417

    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 418: Electrical System

    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 Start relay stuck See your authorized dealer. Run After Engine Starts Starter solenoid stuck See your authorized dealer.

  • Page 419

    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 is Bulb Replace bulb. Inoperative Fuse Replace fuse. Sender Do sender check.

  • Page 420: Mode Selection

    TROUBLESHOOTING MODE SELECTION 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 See your authorized dealer. Monitor) Main controller (MC) See your authorized dealer. Solenoid valve unit See your authorized dealer.

  • Page 421: Control Levers

    TROUBLESHOOTING CONTROL LEVERS Problem Cause Solution Moves Hard Corroded joint See your authorized dealer. Worn out pusher 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 422

    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 See your authorized dealer. components Oil Foams Air leak in line from reservoir to pump Repair leak or see your authorized dealer.

  • Page 423

    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 424

    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 425: Specifications (backhoe)

    SPECIFICATIONS SPECIFICATIONS (BACKHOE) ZX450LC M1J1-12-001 Model ZX450LC Type of Front-End Attachment 3.4 m (11 ft 2 in) Arm Bucket Capacity (Heaped) PCSA 2.07 m (2.71 yd ), CECE 1.8 m Operating Weight 46600 kg (102700 lb) Base Machine Weight 36500 kg (80500 lb) Engine 260 kW/1800 min (353 PS/1800 rpm)

  • Page 426: Working Ranges (backhoe)

    SPECIFICATIONS WORKING RANGES (BACKHOE) ZX450LC M1J1-12-002 Category 7.0 m (23 ft 0 in) Boom 8.2 m(26 ft 9 in)Boom 2.9 m (9 ft 6 in) Arm 3.4 m (11 ft 2 in) Arm 3.9 m (12 ft 10 in) Arm 4.9 m (16 ft 1 in) Arm 4.9mm (16 ft 1 in) Arm Backhoe...

  • Page 427: Shoe Types And Applications

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZX450LC Shoe Width mm (in) 600 mm (24") 750 mm (30") 900 mm (35") Grouser Shoe Grouser Shoe Grouser Shoe Application For Ordinary Ground For Weak Footing (Option) For Weak Footing (Option) (Standard) Operating Weight 46600 47400 48100...

  • Page 428: Bucket Types And Applications (backhoe)

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS (BACKHOE) ZX450LC Bucket Capacity Front-End Attachment 8.2 m Bucket Width mm (in) 7.0 m (23’ 0”) Boom (26’ 10”) Bucket (With side cutter) Boom PCSA CECE (Heaped) (Heaped) 2.9 m 3.4 m 3.9 m 4.9 m 4.9 m (9'6") (11’2”)

  • Page 429: Specifications

    SPECIFICATIONS SPECIFICATIONS ZX650LC -3 M1J7-12-001 Model ZX650LC Type of Front-End Attachment 3.6 m Arm Bucket Capacity (Heaped) PCSA 2.9 m (3.8 yd ), CECE 2.5 m Operating Weight 65900 kg (145000 lb) Base Machine Weight 50800 kg (112000 lb) Engine 345 kW/1800 min (469 PS/1800 rpm) –1...

  • Page 430: Working Ranges

    SPECIFICATIONS WORKING RANGES ZX650LC -3 M1J7-12-003 7.8 m Boom 6.8 m BE-Boom 9.2 m Boom Category Item 3.6 m Arm 4.2 m Arm 2.9 m BE-Arm 5.3 m Arm A: Maximum Digging 13250 13850 11800 16170 Reach (ft·in) (43’ 6”) (45’...

  • Page 431

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZX650LC -3 650 mm (26”) 750 mm (30”) 900mm(35”) Shoe Width mm (in) Grouser Shoe Grouser Shoe Grouser Shoe Application For Ordinary Ground For Weak Footing For Weak Footing (Standard) (Option) (Option) Operating Weight 65900 66500 67500 (lb)

  • Page 432: Bucket Types And Applications

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS ZX650LC -3 Bucket Capacity Bucket Width Front-End Attachment mm (in) Weight 6.8 m 7.8 m 9.2 m Bucket BE-Boom Boom Boom PCSA CECE Without side With side (lb) (Heaped) (Heaped) cutter cutter 2.9 m 3.6 m 4.2 m 5.3 m BE-arm...

  • Page 433

    SPECIFICATIONS SPECIFICATIONS (BACKHOE) ZX850LC -3 M1JB-12-001 Model ZX850LC Type of Front-End Attachment 3.7 m (12 ft 2 in) Arm Bucket Capacity (Heaped) PCSA 3.5 m (4.58 yd ), CECE 3.1 m Operating Weight 82200 kg (181200 lb) Base Machine Weight 62700 kg (138200 lb) Engine Isuzu AH-6WG1XYSA-3 397 kW/1800 min...

  • Page 434

    SPECIFICATIONS WORKING RANGES (BACKHOE) ZX850LC -3 M1JB-12-002 Category 8.4 m (27 ft 7 in) 7.1 m Boom (23 ft 4 in) BE-Boom 3.7 m (12 ft 2 in) 4.4 m (14 ft 5 in) 2.95 m (9 ft 8 in) Be-Arm Item Backhoe...

  • Page 435

    SPECIFICATIONS SHOE TYPES AND APPLICATIONS ZX850LC Shoe Width mm (in) 650 mm (26") 750 mm (30") 900 mm (35") Grouser Shoe Grouser Shoe Grouser Shoe Application For Ordinary Ground For Weak Footing (Option) For Weak Footing (Option) (Standard) Operating Weight 82200 82900 83900...

  • Page 436

    SPECIFICATIONS BUCKET TYPES AND APPLICATIONS (BACKHOE) ZX850LC Bucket Capacity Bucket Width Front-End Attachment mm (in) m (ft•in) 7.1 m (23’4”) 8.4 m (27’ 7”) Weight Bucket Without With side BE-Boom Boom kg (Ib) PCSA CECE side cutter, cutter, (Heaped) (Heaped) 2.95 m (9'8") 3.7 m (12’2”) 4.4 m (9’8”)

  • Page 437: 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) ZX450LC ZX650LC ZX850LC 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 0.5 m/s...

  • Page 438

    SPECIFICATIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-14...

  • Page 439

    OPTIONAL ATTACHMENTS AND DEVICES COUNTERWEIGHT REMOVAL IMPORTANT: This machine is equipped with 2 shutoff valves for the counterweight removal/ install system. Refer to the shutoff valve orientation table for proper shutoff valve settings. M116-06-019 Shutoff Valve Orientation Table NORMAL COUNTERWEIGHT COUNTERWEIGHT WORKING OPERATION...

  • Page 440

    OPTIONAL ATTACHMENTS AND DEVICES 11. Set variable orifice (6) by turning in the direction of the arrow until closed. Then open orifice (6) 2 turns (ZX450LC , 650LC ), 4-1/2 turns (ZX850LC IMPORTANT: Linkage pivot areas may bind if not properly lubricated resulting in failure of lift cylinder (9) to raise counterweight to ZX450LC...

  • Page 441

    OPTIONAL ATTACHMENTS AND DEVICES 14. Make sure length (A) is correct and lock nuts (10) are not loose. Length A ZX450LC : 105±2 mm (4.13±0.08 in) ZX650LC : 102±2 mm (4.02±0.08 in) ZX850LC : 110±2 mm (4.33±0.08 in) ZX450LC 650LC M1J3-NACW1-007 ZX850LC M1J3-NACW1-014...

  • Page 442

    OPTIONAL ATTACHMENTS AND DEVICES CAUTION: To insure good footing and visibility, always stand on the machine catwalk when operating counterweight pilot control valve. IMPORTANT: To prevent possible damage to hydraulic cylinder lines and adjustable orifice canister, cylinder guard (See step 10) must be removed before lowering the counterweight.

  • Page 443

    OPTIONAL ATTACHMENTS AND DEVICES NOTE: Lifting yokes must be in the forward position or highest point of the slot. 23. Slowly move the counterweight pilot valve lever UP until counterweight bottom bosses (21) move away from machine mainframe (20) approximately 2 to 5 mm (0.1 to 0.2 in) (A). This will ensure that the weight of the counterweight is on the lift cylinder.

  • Page 444

    OPTIONAL ATTACHMENTS AND DEVICES 26. Slowly lower counterweight to the ground until all weight is removed from the linkage and the yokes move freely in their slots. IMPORTANT: Do not operate the pilot control valve with full stroke of lever. Move the cylinder as slowly as possible.

  • Page 445: Counterweight Installation

    OPTIONAL ATTACHMENTS AND DEVICES COUNTERWEIGHT INSTALLATION IMPORTANT: This machine is equipped with 2 shutoff valves for the counterweight removal/ install system. Refer to the shutoff valve orientation table for proper shutoff valve M116-06-029 settings. Shutoff Valve Orientation Table NORMAL COUNTERWEIGHT COUNTERWEIGHT WORKING OPERATION...

  • Page 446

    OPTIONAL ATTACHMENTS AND DEVICES CAUTION: To insure good footing and visibility, always stand on the machine catwalk when operating counterweight pilot control valve. 13. Install counterweight lifting yoke-to-link pins (10) to counterweight pin brackets (11). Slide yoke (9) forward to the top position of the slot in the counterweight pin bracket.

  • Page 447

    OPTIONAL ATTACHMENTS AND DEVICES 17. Slowly raise the counterweight until the counterweight bosses bottom are align mainframe holes, and space between counterweight bosses and mainframe is 5 to 10 Check that bolt (12) can be inserted in the mainframe to install spacer and nut.

  • Page 448

    OPTIONAL ATTACHMENTS AND DEVICES 26. Make sure the counterweight lift arms are below the top cover of the counterweight and are not touching the counterweight plate from inside. Make sure yoke connected to the counterweight pin brackets are not tight. (If necessary, lower or raise cylinder slightly to meet above requirements and check again torques.) 27.

  • Page 449: Counterweight Removal/install Device Alarm

    OPTIONAL ATTACHMENTS AND DEVICES Counterweight Removal/Install Device Alarm (Optional) When oil pressure in the counterweight remove/install device cylinder increases, the buzzer sounds and icon (A) is displayed on the monitor. CAUTION: If the machine is operated with the buzzer sounds and icon displayed, the counterweight removal/install device may have serious trouble.

  • Page 450

    OPTIONAL ATTACHMENTS AND DEVICES ZX450LC (BACKHOE) Packing Dimensions and Weights for Transportation - 1 Base Machine WARNING: 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 451

    OPTIONAL ATTACHMENTS AND DEVICES Packing Dimensions and Weights for Transportation - 2 A’ Base Machine Weight: 33400 kg (73600 lb) 3420 Shoe A’ Overal Width Weight kg (lb) (11’ 3”) Width mm (ft•in) mm (ft•in) mm (ft•in) With With mm (in) With With Removal...

  • Page 452

    OPTIONAL ATTACHMENTS AND DEVICES Packing Dimensions and Weights for Transportation - 3 A’ Base Machine Weight: 28600 kg (63100 lb) 3420 A’ Overal Width Weight kg (lb) Shoe mm (ft•in) mm (ft•in) mm (ft•in) With With (11’ 3”) Width With With Removal Removal...

  • Page 453

    OPTIONAL ATTACHMENTS AND DEVICES Counterweight 2960 mm (9’ 9”) Weight: 8230 kg (18100 lb) Height: 1340 mm (4’ 5”) 710 mm (28”) M1J3-NACW1-018 Side Step (Front) 515 mm Weight: 44 kg (97 lb) (20”) Height: 150 mm (6”) 2340 mm (7’ 8”) Side Step (Rear) 515 mm Weight: 30 kg (66 lb)

  • Page 454

    OPTIONAL ATTACHMENTS AND DEVICES ZX650LC Types of Packings for Transportation <Type 1> <Type 2> Base Machine without Base Machine without Front Front Attachment and Side Attachment Frames Counterweight Two Side Frames Boom Counterweight Boom Bucket Two Boom Cylinders Bucket Four Hydraulic Hoses Two Boom Cylinders Two Side Steps Four Hydraulic Hoses...

  • Page 455

    OPTIONAL ATTACHMENTS AND DEVICES ZX650LC (BACKHOE) Packing Dimensions and Weights for Transportation - 1 Base Machine (Without front attachment) WARNING: 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 456

    OPTIONAL ATTACHMENTS AND DEVICES Boom Overall Boom Length Weight Width m (ft•in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 6.80 (22’4”) 7140 2510 1390 6110 BE-Boom (23’5”) (8’3”) (4’7”) (13500) 8130 2330 1390 6550 7.80 (25’7”) Standard Boom (26’8”) (7’8”) (4’7”) (14400)

  • Page 457

    OPTIONAL ATTACHMENTS AND DEVICES Boom Cylinder Weight: 550 kg × 2 (1210 lb × 2) 2830 mm (9’ 3”) 550 mm (21”) M17V-06-026 Hose 1150 mm (3’ 9”) Weight: 7 kg × 2 (15 lb × 2) 10 kg × 2 (22 lb × 2) 1150 mm (3’...

  • Page 458

    OPTIONAL ATTACHMENTS AND DEVICES Handrail on the Side Hydraulic Oil Tank Weight: 24 kg (53 lb) Height: 400 mm (16”) 760 mm (30”) 2020 mm (6’ 8”) M1J1-06-003 Handrail on the Fuel Tank Weight: 19 kg (42 lb) Height: 1040 mm (3’ 5”) 870 mm (34”) 850 mm (33”)

  • Page 459

    OPTIONAL ATTACHMENTS AND DEVICES Packing Dimensions and Weights for Transportation - 2 Base Machine (Without front attachment, sideframe ) Weight: 20100 kg (44300 lb) A’ With Removal Kit A mm (ft•in) A’ mm (ft•in) With Removal Kit With Removal Bracket mm (ft•in) 5450 (17’...

  • Page 460

    OPTIONAL ATTACHMENTS AND DEVICES Counterweight Weight: 10100 kg (22300 lb) 590 mm Height: 1550 mm (5’1”) (23”) 3360 mm (11’ 0”) M1J3-NACW1-022 Boom Overall Boom Length Weight Width m (ft•in) mm (ft•in) mm (ft•in) kg (lb) mm (ft•in) 6.80 (22’4”) 7140 2510 1390...

  • Page 461

    OPTIONAL ATTACHMENTS AND DEVICES Boom Cylinder Weight: 550 kg × 2 (1210 lb × 2) 2830 mm (9’ 3”) 550 mm (21”) M17V-06-026 Hose 1150 mm (3’ 9”) Weight: 7 kg × 2 (15 lb × 2) 10 kg × 2 (22 lb × 2) 1150 mm (3’...

  • Page 462

    OPTIONAL ATTACHMENTS AND DEVICES Handrail on the Side Hydraulic Oil Tank Weight: 24 kg (53 lb) Height: 400 mm (16”) 760 mm (30”) 2020 mm (6’ 8”) M1J1-06-003 Handrail on the Fuel Tank Weight: 19 kg (42 lb) Height: 1040 mm (3’ 5”) 870 mm (34”) 850 mm (33”)

  • Page 463

    OPTIONAL ATTACHMENTS AND DEVICES ZX850LC (BACKHOE) Types of Packings for Transportation <Type 1> <Type 2> Base Machine without Base Machine without Front Front Attachment and Side Attachment Frames Counterweight Two Side Frames Boom Counterweight Boom Bucket Two Boom Cylinders Bucket Four Hydraulic Hoses Two Boom Cylinders Two Side Steps...

  • Page 464

    OPTIONAL ATTACHMENTS AND DEVICES ZX850LC Packing Dimensions and Weights for Transportation-1 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.

  • Page 465

    OPTIONAL ATTACHMENTS AND DEVICES 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) 8780 2500 1450 8200 8.40 (27’7”) (28’10”) (8’2”) (4’9”) (18100) M17V-06-023 Overall...

  • Page 466

    OPTIONAL ATTACHMENTS AND DEVICES Boom Cylinder Weight: 850 kg × 2 (1870 lb × 2) 2890 mm (9’ 6”) 550 mm (23”) 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 467

    OPTIONAL ATTACHMENTS AND DEVICES Packing Dimensions and Weights for Transportation-2 Base Machine (Without front attachment, side frame, steps on the hydraulic oil tank side and hand rails on A’ the right-hand frame, the fuel tank upper and lubricator upper.) Weight: 28200 kg (62200 lb) With Removal Kit A mm (ft•in) A’...

  • Page 468

    OPTIONAL ATTACHMENTS AND DEVICES Counterweight Weight: 12500 kg (27600 lb) Height: 1790 mm (5’11”) 720 mm (28”) 3360 mm (11’ 0”) M1J3-NACW1-027 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...

  • Page 469

    OPTIONAL ATTACHMENTS AND DEVICES Bucket Bucket Capacity Overall Weight (PCSA Heaped) Width mm (ft•in) mm (ft•in) kg (lb) m³ (yd³) mm (ft•in) 2210 1910 1780 2700 2.9 (3.79) (7’3”) (6’3”) (5’10”) (5950) 2210 1910 2040 2950 3.5 (4.58) (7’3”) (6’3”) (6’8”) (6500) 4.5 (5.89)

  • Page 470

    OPTIONAL ATTACHMENTS AND DEVICES MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 471: Fan Rotation Direction Control System (optional)

    Contents of Alarms ..............1-20 Air Cleaner ..................7-75 Control Lever (4 Way Multi Valve) (Optional) ......5-3 Air Conditioner ................7-85 Control Lever (HITACHI Pattern) ..........5-2 Air Conditioner Operation ............1-64 Control Lever (ISO Pattern) ............5-1 Alarm Light ..................1-12 Control Levers ................11-9 Alarm Occurrence Screen ............1-18...

  • Page 472: Table Of Contents

    INDEX Fuel Rate Display/No Display ...........1-30 Machine Lifting Procedure (ZX650LC ) .......6-17 Fuel System ..................7-65 Machine Lifting Procedure (ZX850LC ) .......6-29 Fuse Box ...................1-63 Mail (Optional) ................1-44 Maintenance Guide ..............7-11 Maintenance Settings ..............1-39 Maintenance Under Special Environmental Conditions .. 9-1 GETTING ON / OFF THE MACHINE ..........

  • Page 473: Starting The Engine In Ordinary Temperature

    INDEX Precaution for Arm Roll-in/Bucket Roll-in Combined Storing the Machine ..............10-1 Operation ................5-16 Support Machine Properly ............S-22 Precautions for Assembling ............6-1 Switch Panel ...................1-48 Precautions for Breaker Operation .........5-22 Switch Panel (Optional Included) ...........1-53 Precautions for Crusher Operation ........5-29 Precautions for Lightening ............

  • Page 474

    INDEX MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................14-4...

  • Page 475

    CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

  • Page 476

    URL:http://www.hitachi-c-m.com PRINTED IN JAPAN (E) 2011, 12 This book is printed on recycled paper.

  • Page 477

    EM1J3-NA1-2 PART NO. 450LC 650LC 850LC Hydraulic -c-m.com PRINTED IN JAPAN (E) 2011, 12 Serial No 020001 and up...

This manual also for:

Zaxis 650lc-3, Zaxis 850lc-3

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  • ramakanth9212 Jan 22, 2018 09:45:
    Please upload Zaxis 650H Parts catalogue.
  • Stefan nation Jun 04, 2017 11:37:
    Where is thermostat​s on 450 LC 3 hitachi zaxis