Hitachi ZAXIS 450-3, 470H-3, 450LC-3, 470LCH-3, 500LC-3, 520LCH-3 Hydraulic Excavator Operator's Manual

Below you will find brief information for Hydraulic Excavator ZAXIS 450-3, Hydraulic Excavator ZAXIS 470H-3, Hydraulic Excavator ZAXIS 450LC-3, Hydraulic Excavator ZAXIS 470LCH-3, Hydraulic Excavator ZAXIS 500LC-3. This manual covers operation and service procedures for the machines. Carefully read and follow all instructions to ensure safety and proper operation of the equipment. The manual includes sections on break-in, driving, operating, assembling, maintenance, troubleshooting, specifications, and more.

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PART NO.

EM1J1-1-1

URL:http://www.hitachi-c-m.com

This book is printed on recycled paper.

0511D48ZX450_470_500 1

PRINTED IN JAPAN (E) 2006, 01

450

-3

470H

-3

450LC

-3

470LCH

-3

500LC

-3

520LCH

-3

Hydraulic Ex ca va tor

Serial No 20001 and up

2006.1.27, 20:14:48

INTRODUCTION

Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

• SI Units (International System of Units) are used in this manual.

For reference MKS system units and English units are also indicated in parentheses after the SI units.

Example : 24.5 MPa (250 kgf/cm

, 3560 psi)

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine

Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, experienced operators officially licensed

(according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

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.

MACHINE

MODEL/TYPE:

PRODUCT

IDENTIFICATION

NUMBER:

PRODUCT IDENTIFICATION NUMBER

PRODUCT

IDENTIFICATION

NUMBER:

NOTE:

*HCM1J100P00020001*

Marks to indicate the start and end of the

PRODUCT IDENTIFICATION

NUMBER (PIN)

ENGINE TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

TRAVEL MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M157-00-001

M111-07-010

M1J1-00-001

M111-12-007

MACHINE NUMBERS

SWING MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

HYDRAULIC PUMP TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

BOOM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

ARM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M16J-07-007

M1J1-001

M111-12-005

M17V-00-005

BUCKET TYPE AND SERIAL NUMBER

MACHINE NUMBERS

TYPE:

MFG. NO.:

M116-12-004

MACHINE NUMBERS

....................................................................................................................................................................................................................................................

CONTENTS

MACHINE NUMBERS

SAFETY

Recognize Safety Information ................................................... S-1

Understand Signal Words ............................................................ S-1

Follow Safety Instructions ........................................................... S-2

Prepare for Emergencies .............................................................. S-2

Wear Protective Clothing ............................................................ S-3

Protect Against Noise ................................................................... S-3

Inspect Machine ............................................................................. S-3

General Precautions for Cab ....................................................... S-4

Use Handholds and Steps ........................................................... S-5

Adjust the Operator’s Seat .......................................................... S-5

Ensure Safety Before Rising from or

Leaving Operator’s Seat ........................................................ S-5

Fasten Your Seat Belt ..................................................................... S-6

Move and Operate Machine Safely .......................................... S-6

Handle Starting Aids Safely ........................................................ S-6

Operate Only from Operator’s Seat ......................................... S-7

Jump Starting .................................................................................. S-7

Keep Riders Off Machine ............................................................. S-7

Precautions for Operations ......................................................... S-8

Investigate Job Site Beforehand ............................................... S-9

Equipment of Head Guard, Rops, Fops ................................S-10

Provide Signals for Jobs Involving

Multiple Numbers of Machines ........................................S-10

Confirm Direction of Machine to Be Driven ........................S-10

Drive Machine Safely ...................................................................S-11

Avoid Injury from Rollaway Accidents ..................................S-13

Avoid Injury from Back-over and Swing Accidents ..........S-14

Keep Person Clear from Working Area .................................S-15

Never Position Bucket Over Anyone .....................................S-15

Avoid Undercutting .....................................................................S-15

Avoid Tipping .................................................................................S-16

Never Undercut a High Bank ....................................................S-16

Dig with Caution ...........................................................................S-17

Operate with Caution .................................................................S-17

Avoid Power Lines ........................................................................S-18

Precautions for Lightening .......................................................S-18

Object Handling ...........................................................................S-18

Protect Against Flying Debris ..................................................S-19

Park Machine Safely .....................................................................S-19

Handle Fluids Safely−avoid Fires ............................................S-19

Transport Safely ............................................................................S-20

Practice Safe Maintenance ........................................................S-21

Warn Others of Service Work ...................................................S-22

Support Machine Properly ........................................................S-22

Stay Clear of Moving Parts ........................................................S-22

Prevent Parts from Flying ..........................................................S-23

Store Attachments Safely ..........................................................S-23

Prevent Burns .................................................................................S-24

Replace Rubber Hoses Periodically ........................................S-24

Avoid High-pressure Fluids .......................................................S-25

Prevent Fires ...................................................................................S-26

Evacuating in Case of Fire ..........................................................S-27

Beware of Exhaust Fumes .........................................................S-27

Precautions for Welding and Grinding .................................S-27

Avoid Heating Near Pressurized Fluid Lines .......................S-28

Avoid Applying Heat to Lines Containing

Flammable Fluids ..................................................................S-28

Remove Paint Before Welding or Heating ...........................S-28

Beware of Asbestos Dust ...........................................................S-29

Prevent Battery Explosions .......................................................S-29

Service Air Conditioning System Safely ...............................S-29

Handle Chemical Products Safely ...........................................S-30

Dispose of Waste Properly .........................................................S-30

SSAFETY SIGNS/Europe/Asia/Middle and

Near East Model Only ........................................................S-31

SAFETY SIGNS/North America and Oceania

Model Only .............................................................................S-38

COMPONENTS NAME ................................................................. 1-1

OPERATOR’S STATION

Getting On / Off the Machine .................................................... 1-2

Cab Features ..................................................................................... 1-3

Multi Function Monitor ................................................................ 1-5

Outline ................................................................................................ 1-6

Menu Screen (23) ..................................................................... 1-9

Hour Meter ...............................................................................1-10

Fuel Gauge ...............................................................................1-10

Clock ...........................................................................................1-10

Back Monitor Selector ..........................................................1-10

Menu Key ..................................................................................1-11

Optional Function Key .........................................................1-11

Return to Basic Screen Key ................................................1-11

Alarm Light ..............................................................................1-11

Optional Function Display ................................................1-11

Coolant Temperature Gauge .............................................1-12

Operating Status Icon Display ..........................................1-12

Alarm Occurrence Screen ..........................................................1-17

Contents of Alarms ......................................................................1-19

Clock Setting ..................................................................................1-21

Attachment Selection

(Only Machines Equipped with Optional Parts) .........1-22

Pump 2 Flow Rate Adjustment

(Only Machines Equipped with Optional Parts) .........1-25

Displaying Operating Conditions ...........................................1-26

Fuel Rate Display/No Display ...................................................1-27

Back Monitor Settings ................................................................1-35

Maintenance Settings .................................................................1-42

Mail (Optional) ...............................................................................1-47

Language Settings .......................................................................1-49

Switch Panel ...................................................................................1-51

Engine Control Dial ......................................................................1-52

Auto-idle Switch ...........................................................................1-52

Power Mode Switch ....................................................................1-53

Travel Mode Switch .....................................................................1-53

CONTENTS

Work Light Switch ........................................................................1-54

Wiper/Washer Switch ..................................................................1-55

Switch Panel (Optional Included) ...........................................1-56

Fan Rotating Direction Device(Optional) ............................1-60

Key Switch .......................................................................................1-61

Power Boost Switch .....................................................................1-61

Horn Switch ....................................................................................1-61

Cigar Lighter ...................................................................................1-62

Cab Light .........................................................................................1-63

Installing Fire Extinguisher (Optional) ..................................1-63

Pilot Control Shut-off Lever ......................................................1-64

Engine Stop Switch ......................................................................1-64

Fuse Box ...........................................................................................1-65

Additional Fuse Box .....................................................................1-65

Air Conditioner Operation ........................................................1-66

Auto Air Conditioner ...................................................................1-67

Cab Heater Operation .................................................................1-72

Cooling Operation .......................................................................1-72

Defroster Operation ....................................................................1-73

Tips for Optimal Air Conditioner Usage ...............................1-74

AM/FM Radio Operation ...........................................................1-75

Digital Clock Setting Procedure ..............................................1-76

Cab Door Release Lever .............................................................1-77

Opening Upper Front Window

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

) .........................................1-77

Closing Upper Front Window ...................................................1-78

Removing and Storing Lower Front Window

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

) .........................................1-79

Opening Side Windows ..............................................................1-79

Opening/closing Overhead Window

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

) .........................................1-80

Opening/closing Overhead Window ....................................1-80

Emergency Exit(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

) .................1-81

Emergency Exit(ZAXIS470H

-3

, 470LCH

-3

, 520LCH

-3

) ........1-82

Adjusting the Seat .......................................................................1-83

Adjusting the Seat (Heater Seat Optional) ..........................1-85

Seat With a Built-in Heater ........................................................1-86

Adjusting the Air-suspension Seat (Optional) ...................1-87

Seat With a Built-in Heater ........................................................1-88

Adjusting Console Height .........................................................1-89

Seat Belt ...........................................................................................1-90

BREAK-IN

Observe Engine Operation Closely .......................................... 2-1

Every 8 Hours or Daily ................................................................... 2-1

After the First 50 Hours ................................................................ 2-1

After the First 100 Hours .............................................................. 2-1

OPERATING the ENGINE

Inspect Machine Daily Before Starting ................................... 3-1

Before Starting Engine ................................................................. 3-2

Level Check ....................................................................................... 3-3

Starting the Engine in Ordinary Temperature ...................... 3-4

Starting in Cold Weather ............................................................. 3-5

Check Instruments After Starting ............................................. 3-6

Using Booster Batteries ................................................................ 3-7

Stopping the Engine ..................................................................... 3-9

DRIVING the MACHINE

Drive the Machine Carefully ....................................................... 4-1

Steering the Machine Using Pedals ......................................... 4-2

Steering the Machine Using Levers ......................................... 4-3

Travel Mode Switch ....................................................................... 4-4

Travel Alarm (Optional) ................................................................ 4-4

Operating on Soft Ground .......................................................... 4-5

Raise One Track Using Boom and Arm ................................... 4-5

Towing Machine a Short Distance ............................................ 4-6

Operating in Water or Mud ......................................................... 4-7

Parking the Machine on Slopes ................................................. 4-8

Parking the Machine ..................................................................... 4-8

OPERATING the MACHINE

Control Lever (ISO Pattern) ......................................................... 5-1

Control Lever (HITACHI Pattern) ................................................ 5-2

Pilot Control Shut-off Lever ........................................................ 5-3

Engine Speed Control ................................................................... 5-6

Auto-idle ........................................................................................... 5-7

Work Mode ....................................................................................... 5-8

Work Mode Select .......................................................................... 5-9

Power Boost ...................................................................................5-10

Power Mode ..................................................................................5-11

Operating Backhoe ......................................................................5-12

Grading Operation .......................................................................5-12

Precaution for Arm Roll-in/ Bucket Roll-in Combined

Operation ................................................................................5-13

Avoid Abusive Operation ..........................................................5-13

Operating Tips ...............................................................................5-14

Select Correct Track Shoes ........................................................5-14

Object Handling --- If Equipped ..............................................5-15

Overnight Storage Instructions ...............................................5-17

ASSEMBLING

Precautions for Assembling ........................................................ 6-1

Precautions for Slinging Work ................................................... 6-3

Precautions for Operating Machine ........................................ 6-4

Installing Counterweight ............................................................. 6-5

Installing Boom Cylinder ............................................................. 6-6

Installing Boom ............................................................................... 6-8

Connecting Hoses Between Boom Cylinder and

Machine ...................................................................................... 6-9

Installing Boom Cylinder Rod ..................................................6-10

Installing Arm ................................................................................6-11

Connecting Arm Cylinder Rod .................................................6-12

Connecting Bucket Cylinder Hoses .......................................6-13

Installing Bucket ...........................................................................6-14

Final Inspection .............................................................................6-15

Transporting by Road .................................................................6-16

Transporting the Machine by Trailer .....................................6-16

Loading/Unloading on a Trailer ..............................................6-16

ZAXIS450

-3

(Backhoe) .................................................................6-20

CONTENTS

ZAXIS470H

-3

(Backhoe) ..............................................................6-24

ZAXIS450LC

-3

(Backhoe) ............................................................6-28

ZAXIS470LCH

-3

(Backhoe) .........................................................6-32

ZAXIS500LCH

-3

(Backhoe) .........................................................6-36

ZAXIS520LCH

-3

(Backhoe) .........................................................6-40

Retracting or Extending the Side Frame ..............................6-44

Retracting the Side Frame .........................................................6-45

Extending the Side Frame .........................................................6-46

MAINTENANCE

Correct Maintenance and Inspection Procedures .............. 7-1

Check the Hour Meter Regularly ............................................... 7-2

Use Correct Fuels and Lubricants ............................................. 7-2

Prepare Machine for Maintenance ........................................... 7-3

Hood and Access Covers .............................................................. 7-4

Periodic Replacement Of Parts .................................................. 7-5

Maintenance Guide ....................................................................... 7-6

A. Greasing ....................................................................................... 7-9

Automatic Lubrication --- If Equipped ...........................7-10

Front Joint Pins (Backhoe) ..................................................7-12

Swing Bearing .........................................................................7-14

Electric Grease Gun --- If Equipped .................................7-15

Swing Internal Gear ..............................................................7-19

B. Engine Oil ...................................................................................7-20

Engine Oil Level ......................................................................7-21

Change Engine Oil ...............................................................7-22

Replace Engine Oil Filter .....................................................7-22

C. Transmission Oil .......................................................................7-24

Swing Reduction Gear .........................................................7-25

Travel Reduction Gear ..........................................................7-26

D. Hydraulic System ....................................................................7-28

Inspection and Maintenance of Hydraulic

Equipment ................................................................................7-29

Check Hydraulic Oil Level ...................................................7-31

Drain Hydraulic Oil Tank Sump .........................................7-32

Change Hydraulic Oil ...........................................................7-33

Suction Filter Cleaning .......................................................7-33

Replace Hydraulic Oil Tank Filter ......................................7-36

Replace Pump Drain Filter ..................................................7-37

Replace Pilot Oil Filter ..........................................................7-38

Replace Air Breather Element ...........................................7-39

Check Hoses and Lines ........................................................7-40

Service Recommendations for Hydraulic Fittings ............7-43

E. Fuel System ...............................................................................7-45

Drain Fuel Tank Sump ..........................................................7-46

Check Water Separator ........................................................7-47

Replace Fuel Main Filter Element .....................................7-50

Replace Fuel Pre-filter Element ........................................7-51

Clean Feed Pump Strainer .................................................7-52

Check Fuel Hoses ...................................................................7-53

F. Air Cleaner ...................................................................................7-54

Clean the Air Cleaner Outer Element .............................7-54

Replace the Air Cleaner Outer and Inner Elements ...7-54

G. Cooling System ........................................................................7-56

Check Coolant Level .............................................................7-58

Change Coolant .....................................................................7-59

Clean Radiator/ Oil Cooler/ Inter Cooler/

Fuel Cooler Core .....................................................................7-60

Clean Oil Cooler Front Screen ...........................................7-60

H. Air Conditioner ........................................................................7-61

Clean and Replace Air Conditioner

Filter Clean Filter ....................................................................7-62

Check Refrigerant (Gas) Quantity ....................................7-64

Check Compressor Belt Tension .......................................7-64

Clean Condenser Core .........................................................7-65

Check Looseness at Each of Fastened Areas ................7-65

Check in-season and Off-season ......................................7-66

I. Electrical System ........................................................................7-67

Batteries ....................................................................................7-68

Replace Batteries ...................................................................7-71

Replacing Fuses ......................................................................7-72

Fuse Box ....................................................................................7-72

Additional Fuse Box ..............................................................7-72

J. Miscellaneous ............................................................................7-74

Check Bucket Teeth ...............................................................7-75

Change Bucket .......................................................................7-78

Adjust the Bucket Linkage (Backhoe) ............................7-79

Remove the Travel Levers ...................................................7-80

Check and Replace Seat Beltcheck .................................7-80

Check Windshield Washer Fluid Level ............................7-80

Check Track Sag .....................................................................7-81

Clean Cab Floor --- As Necessary .....................................7-83

Check Tightening Torque of Bolts and Nuts ................7-84

Check O-rings in Bucket Joints .........................................7-97

Retighten Cylinder Head Bolt ...........................................7-98

Inspect and Adjust Valve Clearance ................................7-98

Check Fuel Injection Timing ..............................................7-98

Measure Engine Compression Pressure ........................7-98

Check Starter and Alternator ............................................7-98

Check Water Pump ................................................................7-98

HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT

Hydraulic System ............................................................................ 8-1

Main Circuit ...................................................................................... 8-2

Electrical Circuit .............................................................................. 8-4

Electrical Diagram .......................................................................... 8-5

MAINTENANCE UNDER SPECIAL

ENVIRONMENTAL CONDITIONS

Maintenance Under Special Environmental Conditions .. 9-1

STORAGE

Storing the Machine ....................................................................10-1

Removing the Machine from Storage ...................................10-2

TROUBLESHOOTING

Engine ...............................................................................................11-1

Electrical System ...........................................................................11-5

Control Levers ................................................................................11-9

Hydraulic System ..........................................................................11-9

CONTENTS

SPECIFICATIONS

Specifications (Backhoe)

ZAXIS450

-3

, ZAXIS450LC

-3

, ZAXIS500LC

-3

....................12-1

Working Ranges (Backhoe)

ZAXIS450

-3

, ZAXIS450LC

-3

..................................................12-2

ZAXIS500LC

-3

..........................................................................12-3

Shoe Types and Applications ...................................................12-4

ZAXIS450

-3

...............................................................................12-4

ZAXIS450LC

-3

..........................................................................12-4

ZAXIS500LC

-3

..........................................................................12-5

Bucket Types and Applications (Backhoe) ..........................12-6

ZAXIS450

-3

, ZAXIS450LC

-3

..................................................12-6

ZAXIS500LC

-3

..........................................................................12-6

Specifications (Backhoe) ............................................................12-7

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

...........12-7

Working Ranges (Backhoe) .......................................................12-8

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

...........12-8

Shoe Types and Applications ...................................................12-9

ZAXIS470H

-3

............................................................................12-9

ZAXIS470LCH

-3

.......................................................................12-9

ZAXIS520LCH

-3

.................................................................... 12-10

Bucket Types and Applications (Backhoe) ....................... 12-11

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

........ 12-11

Lifting Capacities ....................................................................... 12-12

Sound Level Results (2000/14/EC) ...................................... 12-16

Vibration Level ............................................................................ 12-16

OPTIONAL ATTACHMENTS and DEVICES

Hydraulic Breaker .........................................................................13-1

Work Mode .....................................................................................13-2

Breaker Operation ........................................................................13-3

Precautions for Breaker Operation .........................................13-5

Breaker Maintenance ..................................................................13-9

Replace Breaker Circuit Return Oil Filter ........................... 13-11

Hydraulic Crusher ...................................................................... 13-12

Stop Valve Operation ............................................................... 13-13

Three-way-valve Operation (Machines Equipped with the Piping Common to Hydraulic Breaker and Crusher Operation) ................................................... 13-14

Flow Combining Valve Operation ....................................... 13-14

Precautions for Crusher Operation ..................................... 13-15

INDEX ...............................................................................................14-1

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

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION

- are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION

safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

• NOTE indicates an additional explanation for an element of information.

002-E01A-1223

S-1

SA-688

SA-1223

SAFETY

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void 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, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void

Hitachi Warranty Policy.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

003-E01B-0003

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

004-E01A-0437

S-2

SA-003

SA-437

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

Wet weather gear

Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434

INSPECT MACHINE

• Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

S-3

SA-438

SA-434

SA-435

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.

• Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

S-4

SAFETY

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

008-E01A-0439

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.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

• Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING OPERATOR’S SEAT

• Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

S-5

SA-439

SA-378

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. If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every three years regardless of its apparent condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid.

• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

• Do not incinerate or puncture a starting fluid container.

036-E01A-0293-3

S-6

SA-237

SA-426

SA-293

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.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control levers are in neutral.

• Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

012-E01B-0431

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine. Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

014-E01B-0427

S-7

SA-444

SA-032

SA-379

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.

Always beware of the surroundings while operating.

When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles.

• When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M104-05-015

S-8

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.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary.

Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

• Make sure the worksite has sufficient strength to firmly support the machine.

When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.

• If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.

• Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine.

• Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:

• Reduce the engine speed.

• Select slow travel speed mode.

• Operate the machine slowly and be cautious with machine movements.

S-9

SA-380

SAFETY

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or

FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect travel pedal/lever operation may result in serious injury death.

• Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front.

017-E01A-0491

S-10

SA-490

SA-481

SA-491

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.

Don’t allow personnel to stay around the machine while traveling.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

• Never attempt to ascend or descend 35 degrees or steeper slopes.

• Be sure to fasten the seat belt.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-657

SA-658

SA-441

SA-442

S-11

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.

• Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.

• If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral.

Then, restart the engine.

• Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

• Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Before moving machine, determine which way to move travel pedals/levers for the direction you want to go.

When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.

An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction.

• Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.

• Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.

• Use wood plates in order not to damage the road surface.

Be careful of steering when operating on asphalt roads in summer.

• When crossing train tracks, use wood plates in order not to damage them.

• Do not make contact with electric wires or bridges.

• When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.

• When traveling on rough terrain, reduce engine speed.

Select slow travel speed. Slower speed will reduce possible damage to the machine.

• Avoid operations that may damage the track and undercarriage components.

• During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping.

Arrow -mark

S-12

Travel Motor

M104-05-008

M178-03-001

SA-011

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.

• Lower the bucket and/or other work tools to the ground.

• Turn the auto-idle switch and the H/P mode switch off.

• Run the engine at slow idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and remove the key from the key switch.

• Pull the pilot control shut-off lever to LOCK position.

• Block both tracks and lower the bucket to the ground.

Thrust the bucket teeth into the ground if you must park on a grade.

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E02A-0493

SA-391

SA-392

S-13

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:

• Always look around BEFORE YOU BACK UP AND SWING

THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE

CLEAR.

• Keep the travel alarm in working condition (if equipped).

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE

WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN

BYSTANDERS BEFORE MOVING MACHINE.

• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW

IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN

VIEW.

Use hand signals, which conform to your local regulations, when work conditions require a signal person.

• No machine motions shall be made unless signals are clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the operator’s manual.

021-E01A-0494

SA-383

SA-384

S-14

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.

• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

023-E01A-0487

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

024-E01A-0488

S-15

SA-386

SA-487

SA-488

SAFETY

AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-

CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL

RESULT

MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP

FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:

• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

025-E03B-0463

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing serious injury or death.

026-E01A-0519

S-16

SA-012

SA-440

SA-489

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.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

027-E01A-0382

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the boom or arm.

028-E01A-0389

SA-382

SA-389

S-17

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.

• Check and comply with any local regulations that may apply.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

029-E01A-0381

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

OBJECT HANDLING

• If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upperstructure with the travel motors at the rear.

• Move the load slowly and carefully. Never move it suddenly.

• Keep all persons well away from the load.

• Never move a load over a person's head.

• Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

032-E01A-0132

S-18

SA-381

SA-1088

SA-014

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.

031-E01A-0432

PARK MACHINE SAFELY

To avoid accidents:

• Park machine on a firm, level surface.

• Lower bucket to the ground.

• Turn auto-idle switch and H/P mode switch OFF.

• Run engine at slow idle speed without load for 5 minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Pull the pilot control shut-off lever to the LOCK position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

HANDLE FLUIDS SAFELY−AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler cap.

034-E01A-0496

S-19

SA-432

SA-390

SA-018

SA-019

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.

• Be sure to use a signal person.

• Always follow the following precautions for loading or unloading:

1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode switch.

5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.

6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

8. Place blocks in front of and behind the tracks. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANS-

PORTING section.

035-E07A-0454

SA-395

S-20

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.

• Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine:

1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

7. Remove the key from the switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Pull the pilot control shut-off lever to the LOCK position.

10. Allow the engine to cool.

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• If the machine must be raised, maintain a 90 to 100˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the

“MAINTENANCE” chapter of this manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

500-E02C-0520

S-21

SA-028

SA-527

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.

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do

Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

501-E01A-0287

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

S-22

SA-037

SS2045102

SA-527

SA-026

SAFETY

PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or VALVE AS-

SEMBLY.

• As pieces may fly off, be sure to keep body and face away from valve.

• Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death.

• Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-344

SA-034

S-23

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.

• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of

“Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

S-24

SA-039

SA-225

SA-019

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.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

507-E03A-0499

SA-031

SA-292

SA-044

S-25

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.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc..

Clean up Flammables:

• Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch:

• If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day:

1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine.

508-E02A-0393

S-26

SA-019

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.

• Exit the machine.

• In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab.

Refer the explanation pages on the Emergency Evacuation

Method.

18-E02B-0393

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

509-E01A-0016

PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

S-27

SA-016

SA-818

SA-393

SS-1510

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 t

heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING

FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

S-28

SA-030

SA-029

SAFETY

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Don’t use compressed air.

• When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16˚C ( 60˚ F ) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the instructions described on the container for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

513-E01A-0405

S-29

SA-405

SA-029

SA-032

SAFETY

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s (available only in

English) on chemical products used with your machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• 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.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

S-30

SA-309

SA-226

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer.

8 6 2

S-31

SS-2562

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

WARNING!

Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator’s Manual.

If the parked machine is unexpectedly moved, serious injury or death due to crushing may result. Be sure to lower the front attachment to the ground, lock the control levers, and remove the engine key before leaving the machine unattended.

Sign indicates an electrocution hazard if machine is brought too near electric power lines.

Keep a safe distance from electric power lines.

SS-1616

SS4420333

SS-1613

Sign indicates a hazard form falling window.

After raising window, be sure to lock it in place with lock pins.

SS-1618

S-32

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

When moving the seat height/tilt lever downward, press the lever grip with a palm from the top side. Don’t grasp the lever grip to operate the lever, possibly resulting in pinch of your fingers into the seat stand.

If the machine should overturn, the operator may become injured and/or thrown from the cab and/or crushed by the overturning machine.

SS7371371

SS4654287

Don’t extend your hands or head from the window. Your hands or head may come in contact with the boom.

SS4459990

SS3106039

S-33

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

Sign indicates a hazard of being hit by the working device of the machine.

Keep away from machine during operation.

10.

Sign indicates a hazard of a flying plug from track adjuster that could cause injury.

Read manual before adjusting track for safe and proper handing.

11.

Sign indicates a burn hazard from compressed air and spurting hot oil if the oil inlet is uncapped during or right after operation.

Read manual for safe and proper handing.

SS3089581

SS3086091

SS4459928

S-34

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

12.

Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine.

13.

Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.

Allow radiator or hydraulic tank to cool before removing cap.

14.

Sign indicates an explosion hazard.

Keep fire and open flames away from this area.

SS-1614

SS4420336

SS4460067

S-35

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

Sign indicates an electrical hazard from handling the cable.

Read manual for safe and proper handling.

SS4459714

Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte.

SS4460056

S-36

16.

SAFETY SIGNS/Europe/Asia/Middle and Near East Model Only

SS-1022

17.

REFLECTOR (FOR EUROPEAN STANDARD)

SS-1988

18.

Asia/Middle and Near East Model only.

SS-710

S-37

SAFETY SIGNS/North America and Oceania Model Only

4 1

S-38

SS-2819

SAFETY SIGNS/North America and Oceania Model Only

SS-862

SS-863

SS-859

S-39

SAFETY SIGNS/North America and Oceania Model Only

SS3106039

SS3092349

SS-408

S-40

SAFETY SIGNS/North America and Oceania Model Only

SS3077560

SS-1022

SS4371371

S-41

10.

SAFETY SIGNS/North America and Oceania Model Only

11.

SS-024

SS-710

12.

SS3089713

S-42

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

COMPONENTS NAME

M1J1-01-001

1-1

GETTING ON / OFF THE MACHINE

GETTING ON / OFF THE MACHINE

For safety, steps and handrails are provided at various places on the machine. Use them when getting on/off the machine and when inspecting/servicing.

WARNING:

• When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine.

Never jump on or off the machine. Never mount or dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

• Never use the steps or handrails when slinging the cab and/or base machine, or when securing the machine on the track or trailer with wire ropes for the transportation. Doing so may break the steps or handrails, causing serious injury.

M1J1-002

ZAXIS450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

M1J1-003

ZAXIS500LC

-3

, 520LCH

-3

M16J-01-013

1-2

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

11- Radio

12- Operator's Seat

13- Cab Door Release Lever

14- Pilot Control Shut-Off Lever

15- Glove Compartment

16- Fuse Box

17- Cigar Lighter

18- Switch Panel

19- Hot & Cool Box

20- Engine Stop Switch

OPERATOR'S STATION

3 4 5 6

M1J1-01-022

M1U1-01-002

1-3

M1U1-01-029

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

11- Air Conditioner Panel

12- Radio

13- Operator's Seat

14- Cab Door Release Lever

15- Pilot Control Shut-Off Lever

16- Glove Compartment

17- Fuse Box

18- Cigar Lighter

19- Switch Panel

20- Hot & Cool Box

21- Engine Stop Switch

OPERATOR'S STATION

3 4 5 6 7

M1J1-01-026

M1U1-01-002

1-4

M1U1-01-029

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.

Key Switch: ON

T1V1-05-01-115

IMPORTANT: After the engine starts and the alternator starts generating power. Alternator alarm is displayed on the basic screen.

Alternator Alarm

Basic Screen

M1J1-01-002

M1J1-03-005

1-5

OPERATOR'S STATION

OUTLINE

1 - Work Mode Display

2 - Auto-Idle Display

3 - Overload Alarm Display

(Optional)

4 - Auto-Lubrication Display (Optional)

5 - Auxiliary

6 - Preheat Display

7 - Work Mode Display

8 - Hour Meter

9 - Auxiliary

10 - Fuel Gauge

11 - Mail Display (Optional)

12 - Auto-Lubrication Display (Optional)

13 - Fuel Rate Display

14 - Clock

15 - Back Monitor Selector (Optional)

16 - Menu

17 - Auto-Lubrication Selection (Optional)

18 - Mail Selection (Optional)

19 - Auxiliary

20 - Work Mode Selection

21 - Return to Basic Screen Key

22 - Coolant Temperature Gauge

21 20 19

4 5

M1J1-01-003

1-6

• Display of Meters

Items to be displayed

8. Hour Meter

10. Fuel Consumption Gauge

14. Clock

16. Menu

22. Coolant Temperature Gauge

OPERATOR'S STATION

Work Mode

• Work Mode Display

The attachments being used are displayed.

Digging Mode

Attachment Mode

Breaker

T1V1-05-01-108

M1J1-01-004

M1J1-05-001

1-7

OPERATOR'S STATION

• Auto-Idle Display(2)

When selecting auto-idle from the switch panel, the autoidle display (2) is displayed.

When the key is turned ON, the data blinks for 10 seconds.

2 3 4 6

• Overload Alarm Display (3) (optional)

T1V1-05-02-002

The system measures the load of suspended load from the bottom pressure of boom cylinder. When overload is detected, an alarm is displayed.

• Auto-Lubrication Display (4) (Optional)

When selecting auto-lubrication from the switch panel, the auto-lubrication display (4) is displayed.

• Preheat Display (6)

While the current is supplying to the glow plug, the preheat display (6) is displayed.

• Fuel Rate Display (13)

Fuel consumption is displayed. (Reference value)

M1J1-01-003

1-8

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

1-9

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).

Fuel Gauge

The fuel amount in the fuel tank is indicated. Refuel before the needle reaches “E”.

Clock

Indicates the present time.

Back Monitor Selector

Shifts the monitor screen to the back view monitor screen and vice versa.

NOTE: It is optional in some region.

M1U1-01-038

M1U1-01-039

M1U1-01-040

M1U1-01-041

1-10

Menu Key

Shifts the basic screen to the menu screen.

OPERATOR'S STATION

Optional Function Key

The desired preset optional function can be selected by operating these keys even though the menu key is not operated.

F1 : Work Mode Selection

F2 : Auxiliary

F3 : Mail (Optional)

F4: Auto-Lubrication (Optional) are the fixed function keys.

Return to Basic Screen Key

Allows any screen to return to the basic screen.

Alarm Light

Comes ON when any abnormalty occurs.

Optional Function Display

Displays the optional functions preset by the optional function key.

F1 : Work Mode Selection

F2 : Auxiliary

F3 : Mail (Optional)

F4: Auto-Lubrication (Optional)

M1U1-01-042

M1U1-01-043

M1U1-01-044

M1U1-01-045

M1J1-01-005

1-11

OPERATOR'S STATION

Coolant Temperature Gauge

Indicates the engine coolant temperature. Normally the needle is around the center of the scale during operation.

Operating Status Icon Display

Displays icons indicating the current status of the attachment

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

1 2 3 4

M1U1-01-047

M1J1-01-006

1-12

OPERATOR'S STATION

Displaying Basic Screen by 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.

1. Turn the key switch ON. After the starting screen is displayed, the password input screen will be displayed.

Starting Screen

T1V1-05-01-115

2. Input a password by using the keys located under the screen. If pushing the determination key, the monitor unit matches the input password to the registered one. If they match, the basic screen displays.

NOTE: When inputting the password again, the entered characters can be erased by pushing the delete key.

Password Input Screen

T1V5-05-01-093

Determination Key

Delete Key

T1V5-05-01-002

1-13

Basic Screen M1J1-05-001

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

2. Return to the password input screen, by pushing the back key.

NOTE: When inputting the password again, the entered characters can be erased by pushing the delete key.

Determination Key Delete Key

T1V5-05-01-002

Back key

T1V5-05-01-004

T1V5-05-01-093

1-14

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.

4. After thirty seconds, if the key switch is turned to the ON position, the starting screen displays and the password input screen displays again. Then a password can be input again. If inputting an incorrect password even once this time, the security lock screen displays again and a buzzer rings for thirty seconds. The buzzer does not stop ringing for thirty seconds even if turning the key switch

ON/OFF.

Security Lock Screen

T1V5-05-01-005

Starting Screen

T1V1-05-01-115

5. After the buzzer stops ringing, a password can be input again. Turn the key switch to the ON position and input a password after the password input screen displays. (Refer to 1-13)

6. If inputting an incorrect password again, the security lock screen displays again. The buzzer does not stop ringing for thirty seconds even if turning the key switch ON/OFF.

Password Input Screen

T1V5-05-01-093

1-15

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.

1. When turn the key switch to the OFF position, the monitor unit displays the password duration screen for ten seconds.

Key 1

Key2

Key3 Key4

Key5

Password Duration Screen (Key Switch: OFF)

T1V1-05-01-012

2. While the password duration screen is still displayed, push a relevant key, and password duration time is set.

Duration time assigned to each key is as follows:

key 1: 0 minute

key 2: 30 minutes

key 3: 60 minutes

key 4: 90 minutes

key 5: 120 minutes

NOTE: If password duration time is not set explicitly, 0 minute on duration time is assumed.

3. If turning the key switch to the ON position within password duration time, the monitor unit displays the basic screen after the starting screen.

Key Switch: ON

T1V1-05-01-115

Basic Screen

M1J1-01-002

1-16

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

• When the number of alarms is three or more

M1J1-01-007

M1J1-01-008

1-17

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.

Push a Relevant Key

M1J1-01-007

T1V5-05-01-013

1-18

CONTENTS OF ALARMS

Display Contents of Alarms

Overheat Alarm

M178-01-036

Engine Warning Alarm

OPERATOR'S STATION

Remedy

Engine coolant temperature has abnormally increased.

Stop operation. Run the engine at slow idle speed o lower the coolant temperature.

Engine or engine related parts are abnormal.

Consult your nearest Hitachi dealer.

M183-01-080

Engine Oil Pressure Alarm Engine oil pressure has decreased. Immediately stop engine. Check engine oil system and oil level.

M178-01-037

Alternator Alarm Electical system is abnormal.

Consult your nearest Hitachi dealer.

M183-01-071

Remaining Fuel Alarm Fuel level is low. Refill fuel as soon as possible.

M178-01-034

Air Filter Clogged Alarm Air filter elements are clogged.

Clean or replace air filter elements.

M183-01-067

Work Mode Alarm Work Mode system is abnormal.

Consult your nearest Hitachi dealer.

T1V1-05-01-102

Pilot Control Shut-Off Lever

Alarm

Pilot control shut-off lever system is abnormal.

Consult your nearest Hitachi dealer.

T1V1-05-01-103

1-19

OPERATOR'S STATION

• Fuel Sensor Error Display

When the fuel sensor is faulty or if the harness between fuel sensor and monitor unit is broken, the fuel sensor error display is displayed on the fuel gauge.

Coolant Temperature

Sensor Error Display

• Coolant Temperature Sensor Error Display

When the coolant temperature sensor is faulty or if the harness between coolant temperature sensor and monitor unit is broken, the coolant temperature sensor error display is displayed on the coolant temperature gauge.

Fuel Sensor Error

Display

M1J1-01-010

1-20

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 located under nation key (5).

keys on icon display area, press determi-

1. While pressing the key located under and keys on icon display area on time setting screen (6), select the figures for Year, Month, Day, and Time.

2. After moving the cursor to position by pressing the key located under key, press determination key (5) to define the setting

T1V5-05-01-019

T1V5-05-01-021

M1J1-01-002

T1V5-05-01-022

1-21

OPERATOR'S STATION

ATTACHMENT SELECTION

(Only Machines Equipped with Optional Parts)

IMPORTANT: Select the attachments from the work mode screen.

In order to display the work mode screen, push key F1 after basic screen displays, or select from main menu.

Selecting an Attachment by Using Key F1

1. When the basic screen displays, push key F1 and display the work mode screen.

Key F1

Basic Screen

2. Push a key located under an attachment mark to be used in order to select the attachment.

(In the right example, Breaker 1 is selected.)

NOTE: When selecting Digging, return to the basic screen.

3. On the attachment specification screen, confirm if specification of the installed attachment agrees with that displayed on the screen.

NOTE: When pushing the back key, return to the previous screen.

4. Push the determination key, and the basic screen displays.

Digging

Select Breaker 1

Work Mode Screen

M1J1-01-002

Back Key

M1J5-05-003

1-22

Attachment Specification Screen

Determination key

M1J5-01-011

OPERATOR'S STATION

Selecting an Attachment from Main Menu

1. When the basic screen displays, push the menu key and display main menu.

2. Select work mode from main menu by using keys 1 and

2. Push determination key. Then, the work mode screen displays.

3. Push the key located under an attachment mark to be used in order to select the attachment.

(In the right example, Breaker 1 is selected.)

NOTE: When selecting Digging, return to Main Menu.

4. On the attachment specification screen, confirm if specification of the installed attachment agrees with that displayed on the screen.

NOTE: When pushing the back key, return to the basic screen.

5. Push the determination key, and the basic screen displays.

Key 1

Key 2

Basic Screen

Determination Key

Menu Key

M1J1-01-002

Back Key

M1J5-05-002

Digging

Select Breaker 1

Work Mode Screen

Back Key

M1J5-05-003

1-23

Attachment Specification Screen

Determination key

M1J5-01-011

Attachment Specification Screen

OPERATOR'S STATION

Maximum Pump 2 Flow Rate

Maximum Engine Speed

Flow Combining Switching Valve : OFF

(Refer to the Work Mode of Chapter 5)

M1J5-01-011

Maximum Pump 2 Flow Rate

Maximum Engine Speed

Flow Combining Switching Valve : OFF

(Refer to the Work Mode of Chapter 5)

M1J5-01-012

Maximum Pump 2 Flow Rate

Maximum Engine Speed

Flow Combining Switching Valve : OFF

(Refer to the Work Mode of Chapter 5)

M1J5-01-013

1-24

OPERATOR'S STATION

PUMP 2 FLOW RATE ADJUSTMENT

(Only Machines Equipped with Optional Parts)

IMPORTANT: This operation is effective when attachments are used.

1. When the basic screen displays, push the menu key and display main menu.

2. Select attachment adjustment from main menu by using keys 1 and 2. Push determination key. Then, the attachment adjustment screen displays.

3. Push key 2. Then, the attachment adjustment screen for currently installed attachments displays.

Basic Screen

Menu Key

M1J1-01-002

4. Adjust maximum flow rate of Pump 2 by using keys 1 and

When using breaker 1, 2 or 3, pushing key 1 will decrease

Max flow rate of pump 2 and pushing key 2 will increase respectively.

Key 1

Key 2 Determination Key

T1V5-05-01-019

NOTE: When pushing the back key, return to the previous screen.

5. Push key 6, and the basic screen displays.

After adjusting it, the maximum flow rate of pump 2 that has been described on the attachment specification screen is changed.

Key 1

Key 6

Key 2 Back Key M1J5-01-014

1-25

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. Push the reset key, and display the data reset confirm screen.

When reset the data, push the detemination key.

NOTE: When pushing the back key, return to the previous screen.

IMPORTANT: Total fuel consumption and fuel consumption rate depend on the operating environment and the operation method of machine.

The values shown on the screen are just for reference.

There could arise ± 20% of differences between actual fuel consumption and fuel consumption which is displayed by the monitor unit.

4. Push key 6, and the basic screen displays.

Key 1

Key 2

Basic Screen

Determination Key

Menu Key

M1J1-01-002

T1V5-05-01-019

Reset Key Back Key T1V5-05-01-025

1-26

Key 6

Back Key

Determination Key

T1V5-05-01-026

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.

2. Select fuel rate display/No display from main menu by using keys 1 and 2. Push the determination key. Then, the fuel rate display/No display screen displays.

Basic Screen

Menu Key

M1J1-01-002

3. Push the determination key, and fuel rate display will be set to ON.

NOTE: When pushing the back key, return to the previous screen.

Key 1

Key 2

Determination

Key

Back Key

M1J5-05-002

Determination

Key

Back Key

T1V5-05-01-164

Back Key T1V5-05-01-119

1-27

OPERATOR'S STATION

4. Push key 6, and the fuel rate display will be added to basic screen.

Key 6

T1V5-05-01-119

Fuel Rate

M1J1-01-015

1-28

OPERATOR'S STATION

Fuel Rate No Display

1. When the basic screen displays, push the menu key and display main menu.

Basic Screen

Fuel Gauge

Menu Key

M1J1-01-015

2. Select fuel rate display/No display from main menu by using keys 1 and 2. Push the determination key. Then, the fuel rate display/No display screen displays.

3. Push the determination key, and fuel rate display will be set to OFF.

NOTE: When pushing the back key, return to the previous screen.

Key 1

Key 2 Determination Key

Back Key

M1J5-05-002

Determination Key

Back Key

T1V5-05-01-119

Back Key

T1V5-05-01-164

1-29

OPERATOR'S STATION

4. Push key 6, and return to the basic screen.

Key 6

T1V5-05-01-164

Basic Screen

M1J1-01-002

1-30

OPERATOR'S STATION

• Overload Alarm

(Only machines equipped with optional parts)

IMPORTANT: When using overload alarm, consult your nearest Hitachi dealer.

When the overload alarm switch is turned ON, the system measures load of the suspended load from bottom pressure of the boom cylinder. An alarm message is displayed and buzzer is rung, if overload is detected.

Overload Alarm

Basic Screen

Overload Alarm Switch (Optional)

M1J1-01-016

M1J1-03-001

1-31

OPERATOR'S STATION

Password Change (Optional)

1. After the basic screen is displayed, push the menu key in order to display the main menu.

2. Select password change from main menu by using keys

1 and 2. Push the determination key. Then, the password change screen displays.

Basic Screen

Menu Key

M1J1-01-002

Key 1

Key 2

Determination Key T1V5-05-01-129

T1V5-05-01-041

3. Input the registered password and push the determination key.

4. If inputting the password again, the entered characters can be erased. By pushing the delete key.

Registered Password

Determination Key Delete Key

T1V5-05-01-042

1-32

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.

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.

A New Password

Back Key

T1V5-05-01-044

T1V5-05-01-130

Determination Key Delete Key

T1V5-05-01-131

1-33

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

9. The message “New password has been registered.” displays. This completes the password change process.

Determination Key

Delete Key

T1V5-05-01-133

Key 6

T1V5-05-01-043

10. Push key 6 and the basic screen displays.

Basic Screen

M1J1-01-002

1-34

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.

1. When the basic screen displays, push the menu key and display main menu.

2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.

Basic Screen

Menu Key

M1J1-01-002

3. Select auto-control by using keys 1 and 2. Push the determination key. Then, auto-control is set to ON.

NOTE: When pushing the back key, return to the basic screen.

4. Push key 6, and return to the basic screen.

5. If travel operation is done, backward image is displayed on the screen of monitor unit.

Key 1

Key 2

Determination Key Back Key M1J5-05-002

Key 1

Key 2 Determination Key

Back Key T1V5-05-01-134

1-35

Key 6

Back Key

T1V5-05-01-120

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.

2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.

Basic Screen

Menu Key

M1J1-01-002

3. Select auto-control by using keys 1 and 2. Push the determination key. Then, auto-control is set to OFF.

NOTE: When pushing the back key, return to the previous screen.

4. Push key 6, and return to the basic screen.

Key 1

Key 2 Determination Key

Back Key

M1J5-05-002

Key 1

Key 2

Determination Key Back Key T1V5-05-01-120

1-36

Key 6

Back Key

T1V5-05-01-134

OPERATOR'S STATION

Switching Image Display

• From mirror Image to normal image

1. When the basic screen displays, push the menu key and display main menu.

Basic Screen

Menu Key

M1J1-01-002

2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.

Key 1

Key 2 Determination Key

Back Key M1J5-05-002

3. Select mirror image by using keys 1 and 2. Push the determination key. Then, the setting is switched to normal image.

NOTE: When pushing the back key, return to the previous screen.

Key 1

Key 2

Determination Key Back Key

T1V5-05-01-135

Back Key T1V5-05-01-120

1-37

OPERATOR'S STATION

4. Push the back monitor switching key, and normal image is displayed on the screen.

Back Monitor Selector

T1V5-05-01-120

Normal Image

T1V1-05-01-126

1-38

OPERATOR'S STATION

• From normal image to mirror image

1. When the basic screen displays, push the menu key and display main menu.

2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.

Basic Screen

Menu Key

M1J1-01-002

3. Select normal image by using keys 1 and 2. Push the determination key. Then, the setting is switched to mirror image.

NOTE: When pushing the back key, return to the previous screen.

Key 1

Key 2 Determination Key Back Key M1J5-05-002

Key 1

Key 2

Determination Key Back Key T1V5-05-01-120

Back Key

T1V5-05-01-135

1-39

OPERATOR'S STATION

4. Push the back monitor switching key, and mirror image is displayed on the screen.

Back Monitor Selector

T1V5-05-01-135

Mirror Image

T1V1-05-01-127

1-40

OPERATOR'S STATION

Switching Image Format

IMPORTANT: If changing the rear view camera to one with

PAL image format, change the image format of the back monitor to PAL.

1. When the basic screen displays, push the menu key and display main menu.

2. Select back monitor settings from main menu by using keys 1 and 2. Push the determination key. Then, the back monitor settings screen displays.

3. Select “PAL” for image format by using keys 1 and 2. Push the determination key. Then, the setting of image format is switched to “PAL”.

NOTE: When pushing the back key, return to the previous screen.

4. Push key 6, and return to the basic screen.

Basic Screen

Menu Key

M1J1-01-002

Key 1

Key 2 Determination Key Back Key M1J5-05-002

Key 1

Key 2

Determination Key Back Key T1V5-05-01-120

1-41

Key 6

Back Key

T1V5-05-01-136

OPERATOR'S STATION

MAINTENANCE SETTINGS

1. When the basic screen displays, push the menu key and display main menu.

Basic Screen

Menu Key

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.

3. Select an item to be set from among the list of maintenance settings screen by using keys 1 and 2. Push the determination key. Then, the Interval ON/OFF settings screen displays.

(In the right example, Engine Oil is selected.)

Key 1

Key 2

Determination Key

T1V5-05-01-019

Key 1

Key 2 Determination Key

T1V5-05-01-049

Maintenance Information Display ON/OFF

1. Select ON or OFF for maintenance information display by using keys 1 and 2. Push the determination key.

ON: When time comes to change, a information message is displayed on the screen.

OFF: No information message is displayed.

2. In order to complete setting, push key 6. Then, the basic screen displays.

Key 1

Key 2

Key 6

Determination Key

Interval ON/OFF Settings Screen

T1V5-05-01-052

1-42

OPERATOR'S STATION

Change Interval Settings

IMPORTANT: Change interval can only be set when maintenance information display is set to ON.

1. Select change interval by using keys 1 and 2.

2. Set time for change interval by using keys 3 and 4.

3. Select remaining hours by using keys 1 and 2, and push determination key.

4. The message “Adjust remaining hours to new change interval. OK?” displays. Then, push the determination key.

5. Push key 6, and the basic screen displays.

Key 1

Key 2

Interval ON/OFF Settings Screen

T1V5-05-01-052

Key 1

Key 2

Key 3 Key 4 Determination Key

T1V5-05-01-138

Key 6

Determination Key

T1V5-05-01-139

1-43

Basic Screen

Menu Key

M1J1-01-002

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.

Key 5

Interval ON/OFF Settings Screen

T1V5-05-01-052

Determination Key

T1V5-05-01-140

1-44

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. Finally the basic screen displays.

(In the right example, Hydraulic Oil applies.)

NOTE: For a machine which the basic screen is displayed according to a password on , the scheduled maintenance screen for the item whose change interval has expired displays for three to ten seconds, after the password is input successfully and the determination key is pushed.

And then the basic screen displays.

2. If data is rest, push the reset key while the scheduled maintenance screen is displayed.

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.

NOTE: When pushing the back key while the maintenance information display screen is displayed, return to the basic screen.

NOTE: When pushing the back key while reset screen is displayed, return to the maintenance information display screen.

Starting Screen

T1V1-05-01-115

Back Key

Reset Key

Maintenance Infomation Display Screen

T1V5-05-01-170

Back Key

Reset Screen

Determination

Key

T1V5-05-01-171

1-45

Basic Screen

M1J1-01-002

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 interval has expired displays for three to ten seconds, after the password is input successfully and the determination key is pushed.

And then the basic screen displays.

2. If data is reset, while the scheduled maintenance screen is displayed, select desired item by using keys 1 and 2.

Push the determination key. Then, the maintenance information display screen for the selected item displays.

(In the right example, Hydraulic Oil is selected.)

NOTE: When pushing the back key while the scheduled maintenance screen is displayed, the basic screen displays.

3. Push the reset key while the maintenance information display screen is displayed.

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.

NOTE: When pushing the back key while the maintenance information display screen is displayed, return to the scheduled maintenance screen.

NOTE: When pushing the back key while the reset screen is displayed, return to the maintenance information display screen.

Key 1

Key 2

Starting Screen

T1V1-05-01-115

Back Key

Determination

Key

Scheduled Maintenance Screen

T1V5-05-01-169

Back Key

Reset Key

Maintenance Infomation Display Screen

T1V5-05-01-170

Back Key

Reset Screen

T1V5-05-01-171

1-46

OPERATOR'S STATION

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 key F3 and display mail screen.

2. If pushing a relevant request key, mail information is sent to ICF.

1 - General Request

2 - Fuel Replenishment Request

3 - Service Maintenance Request

4 - Forwarding Request

3. While mail information is sent to ICF, the message “Mail is being delivered.” is displayed on the screen.

4. When ICF completes receives mail information, the message “Mail delivery successful.” is displayed on the screen.

When pushing the back key, return to the mail screen.

5. Then, a mail is sent from the satellite terminal to the central server via the satellite.

NOTE: Depending on machine’s operating environment or position of the satellite on its orbit, the mail may not be sent.

Key F3

2 3

Basic Screen

Mailing Screen

M1J1-01-017

T1V5-05-01-037

T1V5-05-01-038

Back Key

T1V5-05-01-039

1-47

OPERATOR'S STATION

NOTE: When satellite terminal could not receive the mail, the message “Mail delivery failed.” is displayed on the screen.

T1V5-05-01-040

1-48

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. Select a desired language by using keys 1 and 2. Push the determinaion key.

REMARKS: Languages to be displayed on the screen of monitor unit have been selected from twelve languages, namely display languages 1 or

2, at the time of shipping from the factory.

(Refer to the next section)

NOTE: When pushing the back key, return to the previous screen.

4. Push key 6, and the basic screen displays.

Basic Screen

Menu Key

M1J1-01-002

Key 1

Key 2 Determination Key Back Key

M1J5-05-002

Key 1

Key 6 Key 2

Determination Key Back Key

T1V5-05-01-137

1-49

Display Languages 2

Language

English

Spanish

Italian

French

German

Dutch

Russian

Portuguese

Finnish

Swedish

Norwegian

Danish

Lists of Display Language

Display Languages 1

Language Screen Display

Japanese

English

Chinese (Simplified)

Chinese (Traditional)

Korean

Indonesian

Thai

Vietnamese

Myanmarese

Arabic

Persian

Turkish

Screen Display

OPERATOR'S STATION

T1V1-05-01-158

T1V1-05-01-159

T1V1-05-01-160

T1V1-05-01-161

T1V1-05-01-162

T1V1-05-01-163

T1V1-05-01-142

T1V1-05-01-153

T1V1-05-01-154

T1V1-05-01-155

T1V1-05-01-156

T1V1-05-01-157

T1V1-05-01-141

T1V1-05-01-142

T1V1-05-01-143

T1V1-05-01-144

T1V1-05-01-145

T1V1-05-01-146

T1V1-05-01-147

T1V1-05-01-148

T1V1-05-01-149

T1V1-05-01-150

T1V1-05-01-151

T1V1-05-01-152

1-50

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

OPERATOR'S STATION

M1U1-01-015

1-51

OPERATOR'S STATION

ENGINE CONTROL DIAL

Use engine control dial (1) to adjust engine speed.

Turn it clockwise to increase engine speed or counterclockwise to decrease engine speed.

• The fully clockwise position : Fast idle

• The fully counterclockwise position : Slow idle

Slow Idle

Fast Idle

M1U1-01-033

AUTO-IDLE SWITCH

The auto-idle switch (2) sets the engine speed control mode to either Auto-Idle.

• Auto-Idle Mode

When the auto-idle is turned to the A/I ON position, the engine speed is reduced to slow idle speed 4 seconds after releaving all control levers (neutral), reducing the fuel consumption. When the auto-idle mode is selected, auto-idle indicator (3) on the monitor panel lights.

A/I

OFF

A/I

M1U1-01-017

M1J1-05-001

1-52

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.

• P Mode

Use the P mode when general digging work is needed.

• H/P (High Power) Mode

Use the H/P mode when extra horsepower is needed, i.e. when rolling in the arm in excavation work, etc.

TRAVEL MODE SWITCH

Two travel modes, FAST and SLOW, are selected by turning the travel mode switch to either position.

Mark (Fast Speed Mode)

Mark (Slow Speed Mode)

M178-01-013

M178-01-096

1-53

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.

• OFF Position

Work lights (1) and (2) and the instrument panel illumination will turn off.

M178-01-015

M157-01-146

1-54

OPERATOR'S STATION

WIPER/WASHER SWITCH

The wiper and the window washer are operated using the wiper/washer switch.

• Wiper

Turn the wiper/washer switch to the specified position to operate the wiper.

Mid

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.

INT (Slow): The wiper operates at 8-second interval.

INT (Mid): The wiper operates at 6-second interval.

INT (Fast): The wiper operates at 3-second interval.

ON Position: The wiper operates continuously.

NOTE: (1) When the front window (upper) is opened, the wiper and washer will not operate. Even if the front window (upper) is closed, the wiper and washer will not operate until the lock pin on the right side is placed in the lock position. If the front window is opened while during operating the wiper, the wiper will be retracted and the washer function is deactivated.

(2) In case either the wiper or washer is operated with the front window (upper) opened, or if front window (upper) is opened while operating either the wiper or washer, the front window opening alarm buzzer will sound intermittently at one-second intervals. Close the front window

(upper).

• Washer

Press and hold the wiper/washer switch to squirt washer fluid onto the front window. When the wiper/washer switch is pressed for more than 2 seconds, the wiper operates until the switch is released. When the wiper/washer switch is released, the wiper automatically retracts. While operating the wiper in the INT mode, when the wiper/washer switch is pressed, the wiper operation mode is changed to the continuous operation mode.

IMPORTANT: Washer motor may be damaged if wiper/ washer switch is held for more than 20 seconds, or continually operated with no fluid in the washer tank.

1-55

Fast

Wiper

M178-01-016

M1U1-01-018

SWITCH PANEL (Optional included)

OPERATOR'S STATION

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)

• Overload Alarm switch (Optional) (3)

• Boom Mode Switch (4)

• Engine Oil Level / Coolant Level Switch (5)

• Auto-Lubrication Switch (Optional) (6)

• Rear Light Switch (Optional) (7)

• Rotating Light Switch (Optional) (8)

• Fan Rotation Direction Switch (Optional) (9)

• Electric Type control lever Switch (Optional)

• Swing Alarm Deactivation Switch (Optional)

Armrest

Front

Optional Switch

M1J1-03-001

Rear

Switch Location

M1J1-01-027

1-56

OPERATOR'S STATION

Travel Alarm Deactivation Switch (Optional)

The travel alarm buzzer sounds during travel operation.

When push the travel alarm deactivation switch (1) , the travel alarm buzzer function is deactivated.

Seat Heater Switch (Optional)

When seat heater switch (2) is turned ON, the seat surface is heated so that the seat section becomes warm. When the temperature of the seat section is raised to the specified temperature, heating is automatically stopped.

Overload Alarm Switch (Optional)

During lifting load work with overload alarm switch (3) ON, if overloading is detected, the buzzer sounds and overload alarm indicator (12) on the multi-monitor comes ON. Turn the overload alarm switch OFF to deactivate the overload alarm system function.

M1U1-01-035

M1U1-01-011

M1U1-01-010

M1J1-01-016

1-57

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.

Engine Oil Level / Coolant Level Switch

While engine oil level / coolant level switch (5) is turned ON, the engine oil level / coolant level indicator is displayed.

When releasing the engine oil level / coolant level switch , the indicator comes OFF.

Auto-Lubrication Switch (Optional)

When auto-lubrication switch (6) is turned ON, the autolubrication device is activated so that all greasing points except for the bucket joint pins, swing bearing and swing gear are automatically lubricated at regular intervals.

When the switch is turned OFF, the device is deactivated.

Rear Light Switch (Optional)

When rear light switch (7) is turned ON. The rear light at the rear of the cab roof comes ON.

M1J1-01-020

M1J1-03-002

M1J1-01-018

M1U1-01-009

1-58

OPERATOR'S STATION

Rotating Light Switch (Optional)

When the rotating light switch (8) is turned ON, the rotating light provided at the rear on the cab roof comes ON.

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.

Swing Alarm Deactivation Switch (Optional)

The swing alarm system sounds the buzzer and turns the beacon light ON during swing operation. When push the swing alarm deactivation switch is set to the OFF position, the swing alarm buzzer function is deactivated.

Electrical Control Main Switch (Optional)

When the ( ) mark side of electrical control main switch is pressed, the electrical control (grip switch) system becomes operable. When there is no need to use the electrical control

(grip switch) system, press the ( ) mark side of the main switch to avoid mis-operation.

M1U1-01-012

M1J1-01-019

M1U1-01-036

M1U1-01-013

1-59

OPERATOR'S STATION

FAN ROTATING DIRECTION DEVICE(Optional)

When fan rotating direction switch (3) is turned ON, the fan rotates in reverse, and the radiator, the oil cooler, and the inter cooler core can be cleaned.

1. Turn all control levers (1) to neutral with engine running.

Then, pull the pilot control shut-off lever (2) up to the

LOCK position.

2. Turn off the air conditioner switch.

3. Raise the armrest, press fan rotating direction switch (3) to down the engine speed. Then, after approx. 20 seconds, the fan rotates in reverse for approx. 60 seconds.

4. Then, after approx. 20 seconds, the fan rotating direction returns to normal.

IMPORTANT : In case the pilot control shut-off lever (2) is not in the LOCK position, the fan rotating direction switch device deactivates. Air conditioner may be damaged, if the fan rotating direction switch (3) is pressed with using air conditioner.

M1U1-01-025

Armrest

M1J1-03-001

M1J1-01-019

1-60

KEY SWITCH

1- OFF (Engine Off)

2- ACC (Horn, Radio etc.)

3- ON (Engine On)

4- START (Engine Start)

OPERATOR'S STATION

1 2 3 4

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.

The horn continuously sounds as long as the switch is pressed.

M1J1-01-025

1-61

OPERATOR'S STATION

CIGAR LIGHTER

Operation

IMPORTANT: In case cigar lighter (2) does not pop out automatically 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 lighter (2) knob.

3. Cigar lighter (2) knob will return to the original position when cigar lighter (2) becomes usable. Pull the cigar lighter out to use.

4. After using cigar lighter (2), insert cigar lighter (2) into the panel until the knob is seated in the original position.

Using Cigar Lighter (2) Port as External Power Source

Use cigar lighter (2) port to supply power to lighting equipment for servicing the machine.

IMPORTANT: Only 24 V electric power is available from the cigar lighter port on this machine. Never connect accessories that use power other than 24 V. Damage to the batteries and accessories may result.

Don’t supply power to accessories for a long time without running the engine. Failure to do so may discharge the batteries.

1. Pull cigar lighter (2) knob out.

2. Correctly insert the accessory socket into cigar lighter (2) port.

3. Turn key switch (1) to the ACC or ON position. Power is supplied to the connected accessory.

4. After using the accessory, disconnect the accessory socket and insert cigar lighter (2) into the port.

M178-01-049

Left Control Lever

M1U1-01-021

1-62

OPERATOR'S STATION

CAB LIGHT

Turn the cab light ON or OFF by using switch (1).

M1U1-01-022

INSTALLING FIRE EXTINGUISHER (Optional)

A fire extinguisher (2) can be installed at the right rear corner inside the cab. Consult your nearest HITACHI dealer to install a fire extinguisher.

M1J1-01-029

1-63

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.

• Before leaving the operator's seat, always stop the

engine and pull the pilot control shut-off lever up to the LOCK position.

• Also, pull the pilot control shut-off lever up to the

LOCK position when transporting the machine or when the day's work is complete.

• Confirm that the pilot control shut-off lever is in

the LOCK position before starting the engine.

LOCK Position

M1U1-01-025

ENGINE STOP SWITCH

If the engine does not stop even if the key switch is turned OFF due to failure of the machine, move switch (2) located at the front-left side off the seat stand downward to stop the engine.

After operating switch (2), be sure to return the switch back to the upward position.

UNLOCK Position

M1U1-01-024

M1U1-01-029

1-64

OPERATOR'S STATION

FUSE BOX

10- CONTROLLER

9- BACKUP

10A

8- ECM

30A

7- LUBRICATOR

10A

6- OPTION2

10A

5- OPTION1

4- SOLENOID

10A

3- HEATER

20A

2- WIPER

10A

1- LAMP

20A

ADDITIONAL FUSE BOX

20- OPTION3

19- SW. BOX

18- POWER ON

17- AIRCON

16- GLOW. R

15- AUXILIARY

10A

14- PCV

15A

13- LIGHTER

10A

12- ROOM LAMP/RADIO

11- HORN

10A

30- AUTO LUB.

10A

29- LIGHT1

10A

28- SPARE

27- AUXILIARY3

26- QYICK HITCH

25- IMOBI

24- 12V UNIT

10A

23- CAB LAMP REAR

10A

22- CAB LAMP FRONT

10A

21- SEAT HEATER

10A

40- SPARE

39- SPARE

38- SPARE

37- SPARE

36- SPARE

35- SPARE

34- AUXILIARY2

10A

33- WARNING LAMP

10A

32- CAB LAMP FRONT+2

10A

31- SEAT COMPR.

10A

Fuse Box Additional Fuse Box

M1J1-01-021

M1GR-01-003

1-65

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.

• Highest and Lowest Temperature Control

Highest or lowest air temperature in the cab is set by turning either the FH (Full-Heat) or FC (Full-Cool) indicator ON using the temperature control switch.

• Heater Start-Operation Control System

In winter or in cold weather, when starting the engine, the engine coolant is cool and air temperature inside the cab is low. Then, cool air is restricted not to flow in the cab to the minimum (LO) until the coolant is warmed when the front foot vent and /or foot vent is selected.

1-66

OPERATOR'S STATION

AUTO AIR CONDITIONER

Distinctive Feature

• Temperature Control:

Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation.

• Max. Cooling and Heating:

Maximum cooling or heating can be obtained by moving the temperature control switch to the full right or left respectively.

• Preheating:

During preheating the cab in winter with the foot vent selected, the air volume is reduced to Low until the coolant temperature rises to prevent cool air from entering the cab.

1- Control Panel

2- Front Vent

3- Rear Vent

4- Foot Vent

5- Defroster Vent

6- Blower OFF Switch

7- Blower Switch

8- Liquid-Cristal Display (LCD)

9- Temperature Control Switch

10- Mode Switch

11- AUTO Switch

12- Air Conditioner Switch

13- Fresh Air Mode Switch

14- Circulation Mode Switch

NOTE: Except for the foot vent, all vents are provided with louvers to adjust the air flow direction. In addition, the louvers on the front vent and defroster vent can be completely opened and closed by hand.

1 7

14 13

M1U1-01-025

M1U1-01-027

9 10 11

M178-01-017

1-67

OPERATOR'S STATION

Controller Part Name and Function

• Blower OFF Switch (6)

Stops the blower.

When the switch is pressed, all displays (vent mode, settemperature, and blower speed) on the LCD (8) panel will disappear and the blower stops in both the auto and manual modes.

• Blower Switch (7)

Controls the blower speed from Low to High in 6 stages in the manual mode. The blower speed is displayed at the bottom on the LCD (8).

• Increasing Blower Speed

Each time the top side mark “ ” on blower switch (7) is pressed, the blower speed is increased by one increment.

• Decreasing Blower Speed

Each time the bottom side mark “ ” on blower switch (7) is pressed, the blower speed is decreased by one increment.

NOTE: In the AUTO mode operation, the fan speed will be automatically controlled with the fan speed indicator flashing.

• LCD (8)

Displays the set-status of the air conditioner operating temperature, fan speed, and vent mode.

• Temperature Display

Indicates the set-temperature (18 to 32.0 °C, 65 to 90 °F) by 0.5 °C (0.9 °F) increments at the panel center.

• Blower Speed Display

Indicates the blower speed in 6 stages by lighting the segment at the panel bottom.

• Vent Mode Display

Indicates the selected vent mode at the panel top.

The vent modes are as shown below:

: Front/Defroster Vent Mode

: Front/Rear/ Defroster Vent Mode

: Front/Rear/Foot/ Defroster Vent Mode

: Foot Vent Mode

6 7 8

M178-01-017

Vent mode

Temperature

Blower Speed

M178-01-020

1-68

OPERATOR'S STATION

• Temperature Control Switch (9)

Sets the air temperature in the range of 18 to 32.0 °C (65 to

90 °F) in the MANUAL and AUTO modes. Temperature can be set by 0.5 °C (0.9 °F) increments. The set-temperature is displayed on the LCD (8) center.

• Increasing Temperature

Each time the top side mark “ ” on temperature control switch (9) is pressed, the set-temperature is increased by

0.5 °C (0.9 °F) increments.

• Decreasing Temperature

Each time the bottom side mark “ ” on temperature control switch (9) is pressed, the set-temperature is decreased by 0.5 °C (0.9 °F) increments.

• Temperature Control Switch

• Temperature Mode Change (Centigrade ↔ Fahrenheit)

Press both “ ” and “ ” marks on the temperature control switch for longer than 5 seconds at the same time to change the temperature mode (Centigrade ↔ Fahrenheit). (Unit in temperature mode is abbreviated.)

Temperature Mode

Centigrade

Fahrenheit

Display on LCD

18.0 to 32.0

63 to 91

8 9

M178-01-017

1-69

OPERATOR'S STATION

• Diagnostic Function

Functions of each sensor for the A/C and the air vent damper can be diagnosed using this function.

Press both “ ” and “ ” marks on temperature control switch

(9) for longer than 3 seconds at the same time with the fan turned OFF (no air flow) to display the operating conditions of the sensors and dampers as shown below.

Displays on LC D and Trouble Mode

E18

E21

E22

E43

E44

E45

Displays on LCD Trouble Mode

E— No fault

E11

E12

Broken re-circulation air sensor

Short re-circuited circulation air sensor

E13

E14

E15

E16

Broken fresh air sensor

Short circuited fresh air sensor

Broken coolant temperature sensor

Short circuited coolant temperature sensor

E51

Short circuited insolation sensor

Broken air vent sensor

Short circuited air vent sensor

Abnormal air vent damper

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 fan 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.

M178-00-017

1-70

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 Switch (11)

Selects the air conditioner operation mode in either AUTO or MANUAL.

• AUTO Operation Mode

Press AUTO switch (11). When the indicator comes ON, the

AUTO operation mode is selected. In response to the settemperature, the blower speed, vent mode, and ventilation mode are automatically controlled.

• MANUAL Operation Mode

Press AUTO switch (11). When the indicator goes OFF, the

MANUAL operation mode is selected. Air temperature, blower speed, vent mode, and ventilation mode can be selected as desired.

• Air Conditioner Switch (12)

The air conditioner will turn on and the air conditioner indicator will be lit when air conditioner switch (12) is pressed when blower switch (7) is also turned on (any of the blower indicators is ON).

• Fresh Air Mode Switch (13)

When fresh air mode switch (13) is pressed (indicator on), the fresh air vent will be opened and outside air will be routed into the cab.

• Circulation Mode Switch (14)

When circulation mode switch (14) is pressed (indicator on), the fresh air vent will be closed.

Re-circulate the air inside the cab.

Indicator

14 13

8 9 10 11

M178-01-017

1-71

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 tion.)

vent, normally the foot vent is used for heating opera-

After selecting the foot vent mode by operating mode switch (10), set the desired temperature using temperature control switch (9).

If AUTO switch (11) is pressed, warm air will blow out from foot vent (15).

The blower speed can be adjusted manually using blower switch (7).

In addition, if air conditioner switch (12) is turned on while using the cab heater, air in the cab will be also dehumidified.

7 8 9 10 11

M178-01-017

COOLING OPERATION

(Although cool air will flow out of the front/defroster vent , front/rear/defroster vent, or front/rear/foot/de-froster vent, normally the front vent or front/rear/ defroster vent is used for cooling operation.)

After selecting either the front/defroster vent mode or the front/rear/defroster vent mode by operating mode switch

(10), set the desired temperature using temperature control switch (9).

If AUTO switch (11) is pressed and air conditioner switch (12) is ON, cool air will blow out from front/defroster vent or front/ rear/defroster vent.

The blower speed can be adjusted manually using blower switch (7).

In addition, if the outer surface of the lower front window becomes clouded, close defroster vent (3). (The louver on the defroster vent can be closed by hand.)

7 8

M1U1-01-025

9 10 11

M178-01-017

M1U1-01-025

1-72

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.

If AUTO switch (11) is pressed, air will blow out from front/defroster vent or front/rear/defroster vents.

Adjust the louvers on front vent (1) and defroster vent (3) as required.

The blower speed can be adjusted manually using blower switch (7).

Turn on air conditioner switch (12) (indicator will light) if the windows become clouded or if dehumidifying is required.

9 10 11

M178-01-017

M1U1-01-025

1-73

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). Then turn circulation mode switch (14) ON (the indicator lights).

Select the front/rear/defroster vent mode by operating mode switch (10). Set the blower speed to the maximum flow rate (6 segments lit) by operating blower switch (7).

Then, turn air conditioner switch (12) ON (the indicator lights).

After running the engine at a little over 1000 min -1 for a few minutes, press AUTO switch (11) and close the windows.

When Windows Become Clouded

If the insides of the windows become clouded during rainy weather or on humid days, operate the air conditioner to aid in keeping the windows clear. When the atmosphere is very damp, and if the air conditioner has run excessively, the outside of the windows may become clouded. If this happens, turn off the air conditioner to adjust the temperature in the cab.

Off-Season Air Conditioner Maintenance

To protect each part of the compressor from a lack of lubricant, operate the air conditioner at least once a month for several minutes with the engine running at a slow speed during off-season. When the cab temperature is lower than

15°C (59°F), the air conditioner may not operate. If this happens, warm the cab using the heater first.

IMPORTANT: • Do not suddenly increase the engine speed.

• Keep any flames away from the control panel.

• Refer to the item “Check Air Conditioner

Filter” in the Maintenance Section for maintenance of the air conditioner filters.

• Always clean the auto air conditioner sensor for effective air conditioner performance. Avoid placing any obstructions around the sensor.

7 8

Air Conditioner Sensor

9 10 11

M178-01-017

M1J1-01-028

1-74

OPERATOR'S STATION

AM/FM RADIO OPERATION

Controls on the radio

1- Power Switch/Volume Control Knob

2- Tone Adjustment Ring

3- AM/FM Switch

4- Station Presets

5- Tuning Switches

6- Display Mode Change Switch

7- Digital Display

8- Time Set Switches

Tuning Procedure

• Manual Tuning Procedure

Repeatedly tap one of tuning switches (5) until the desired station is reached.

Each time the tuning switch is pressed, the frequency changes at an interval.

Tap the tuning switch [UP] ( ) to increase the frequency.

Tap the tuning switch [DOWN] ( ) to decrease the frequency.

• Automatic Search Function

Press and hold one tuning switch (5) for more than half a second, then release. The frequency display will move up to the next higher frequency station.

To go up to the next higher frequency station, press and hold the tuning switch [UP] ( ).

To go down to the next lower frequency station, press and hold the tuning switch [DOWN] ( ).

In order to deactivate the automatic search function while it is operating (while searching the next available frequency station), simply tap tuning switch (5) again.

If the receiving radio waves are weak, i. e. such as when the machine is located between high rising buildings, etc., use the manual tuning procedure to select the desired station.

3 6 8

7 2

5 1

M1G6-01-026

1-75

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. The frequency of the preset station will be indicated on digital display (7).

Once the presetting is complete for a station preset (4), the radio will be tuned to the preset station when station preset

(4) is pressed (for less than 1 second).

DIGITAL CLOCK SETTING PROCEDURE

NOTE: In order to set the clock, digital display (7) must be in the time display mode.

1. Press display mode button (6) to indicate the hour display on digital display (7).

2. Press and hold time set button (RST) (8) for longer than 1 second. The hour display will start flashing and the time set mode will be selected.

3. Press time set button (H or M) (8) to set the clock. Each time time set button (H or M) (8) is pressed, the time display will increase by one. If time set button (H or M) (8) is pressed and held, the time display will change continuously.

• When setting the hour, pres time set button (H) (8).

• When setting the minute, press time set button (M) (8).

The time is displayed in 12 hour standard.

If either of the switches (H) or (M) is pressed and held, the hour or minute display will change continuously until the switch is released.

4. When the hour display is “12,” if time set button (H) (8) is pressed, the hour display will be reset to “1.” When the minute display is “59,” if time set button (M)(8) is pressed, the minute display will be reset to “00.” However, the hour display remains unchanged in this case.

5. After the clock setting is complete, press and hold time set button (RST)(8) again for longer than 1 second, or turn the radio switch OFF to end the clock time setting procedure. Digital display (7) stops flashing and changes to stay ON.

6 8

M1G6-01-026

1-76

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.

To unlock the door from this position, push down on lever (1).

OPENING UPPER FRONT WINDOW

(ZAXIS450

-3

, 450LC

-3

, 500LC-

-3

)

WARNING: Open or close the upper-front cab window only after pulling up the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to move unexpectedly if a control lever is touched a part of the body by mistake, possibly resulting in personal injury or death.

1. Press lock release lever (3) at the upper center to release the upper front window lock.

NOTE: Use caution when releasing the lock. The upper section of the upper front window will move approx. 10 cm inward.

2. Holding the upper and lower handles (one each) on the upper front window, pull the upper front window up and back until it securely catches into auto lock (2).

CAUTION: Always secure lock pin (4) in the lock position after the upper front window is opened.

3. After confirming that the window securely catches into auto lock (2), slide lock pin (4) into the left bracket boss hole to lock the window in position.

NOTE: When the upper front window is opened, the wiper and washer are inoperable.

M1J1-07-051

M1U1-01-028

M1CC-01-020

M1CC-01-031

1-77

OPERATOR'S STATION

CLOSING UPPER FRONT WINDOW

WARNING: Avoid possible injury while closing window.

Upper front window comes down very forcefully.

Close window only when sitting in the operator's seat.

Guide window down slowly.

1. Pull out lock pin (4) to unlock window.

2. Slightly move the window forward while pushing lock release levers (3) to release auto lock (2).

3. Pull window down slowly until it securely catches into auto lock (2).

NOTE: The wiper and washer won’t operate until the upper front window is completely closed.

M1U1-01-028

M1CC-01-031

1-78

OPERATOR'S STATION

REMOVING AND STORING LOWER FRONT

WINDOW

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

)

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.

3. Store the removed windowpane in the storing position.

After inserting the windowpane into rubbers (2 and 3), slide it sideways securely into rubber (1). Then, push fastener (4) to lock.

M1CC-01-022

1-49-001

OPENING SIDE WINDOWS

Opening Cab Door Window

Slide rear pane to the front.

Cab Door Window

M178-01-061

1-79

OPERATOR'S STATION

OPENING/CLOSING OVERHEAD WINDOW

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

)

Opening

1. Move lock levers (1) toward center of window.

2. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3).

Closing

1. Hold handle (2) and pull window down until “click” sound is heard from locks (1).

Note that the overhead window can be used as an emergency exit.

1-51-001

OPENING/CLOSING OVERHEAD WINDOW

(Clear Hatch: If Equipped)

Opening

1. Move lock levers (1) toward center of window.

2. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3).

Closing

1. Hold handle (2) and pull window down until “click” sound is heard from locks (1).

Note that the overhead window can be used as an emergency exit.

IMPORTANT:

• Replace the clear hatch with a new one every 5 years even if undamaged. In case it was remarkably damaged or has received severe shock loads, replace it even if it has been not in use for 5 years.

• When cleaning the clear hatch, use a neutral detergent. If acidic or alkaline detergent is used, the clear hatch may become discolored or crack.

• Keep organic solvent away from the clear hatch.

Failure to do so may cause the clear hatch to become discolored or crack.

1-80

1-51-002

1-51-001

1-51-002

OPERATOR'S STATION

EMERGENCY EXIT

(ZAXIS450

-3

, 450LC

-3

, 500LC

-3

)

If the operator’s cab door should not open in an emergency, escape in the following methods:

1. Open the front windows. Escape through the windows.

NOTE: See page “OPENING UPPER FRONT WINDOWS” for the opening method of the front windows.

WARNING: Take care not be injured with pieces of broken glass.

2. If the front window is difficult to open, break the front window glass using the emergency evacuation tool (1).

Then, escape through the broken window.

3. If the front window is not available for escaping, break the rear window glass using the emergency evacuation tool. Then, escape through the broken window.

NOTE: Emergency exit decals (2) are affixed to the front and rear windows.

4. If neither of front and rear windows are available for emergency exit, open the overhead window to escape from the cab.

M1U1-01-022

1-51-001

1-52-001

1-81

OPERATOR'S STATION

EMERGENCY EXIT

(ZAXIS470H

-3

, 470LCH

-3

, 520LCH

-3

)

If the operator’s cab door should not open in an emergency, escape in the following methods:

1. Break the rear window glass using the emergency evacuation tool (1). Then, escape through the broken window.

WARNING: Take care not be injured pieces of broken glass.

NOTE: Emergency exit decals (2) are affixed to the rear windows.

M1U1-01-022

M1J1-01-023

1-82

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.

WARNING: Avoid possible injury while operating lever (1). When pushing down lever (1), do not grab it. Fingers may be pinched between lever (1) and the seat stand. Be sure to push on the upper face of lever

(1).

Use lever (1) to adjust the seat height and/or seat angle as follows:

• To adjust the front part of the seat:

Push down lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

• To adjust the rear part of the seat:

Pull up lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

Console and Seat Fore-aft Adjustment

Pull lever (2) to the right to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers. Release lever to lock seat and consoles into position.

NOTE: Seat and console fore-aft adjustment range is 120 mm

(4.7 in) with steps every 20 mm (0.8 in).

Seat Fore-Aft Adjustment

Pull lever (3) to unlock the seat from both consoles. With lever (3), slide the seat to the desired distance from pilot control levers. Release the lever.

NOTE: Seat fore-aft adjustment range is 160 mm (6.3 in) with steps every 16 mm (0.8 in).

Backrest Adjustment

Pull up lever (4) to release backrest lock. Move backrest to the desired position and release the lever.

Warning: Possibility of pinched fingers

Push down with the palm.

SS-955

M1U1-01-029

1-83

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).

M1G6-01-017

1-84

OPERATOR'S STATION

ADJUSTING THE SEAT (HEATER SEAT OPTIONAL)

Seat Height and Angle Adjustment

(1).

Use lever (1) to adjust the seat height and/or seat angle as follows:

• To adjust the front part of the seat:

Push down lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

• To adjust the rear part of the seat:

Pull up lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

Console and Seat Fore-aft Adjustment

Pull lever (2) to the right to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers. Release lever to lock seat and consoles into position.

NOTE: Seat and console fore-aft adjustment range is 120 mm

(4.8 in) with steps every 20 mm (0.8 in).

Seat Fore-Aft Adjustment

Pull lever (3) to unlock the seat from both consoles. With lever (3), slide the seat to the desired distance from pilot control levers. Release the lever.

NOTE: Seat fore-aft adjustment range is 160 mm (6.3 in) with steps every 16 mm (0.8 in).

Backrest Adjustment

Pull up lever (4) to release backrest lock. Move backrest to the desired position and release the lever.

Warning: Possibility of pinched fingers

Push down with the palm.

SS-955

M1U1-01-029

1-85

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).

SEAT WITH A BUILT-IN HEATER

Raise the armrest, the heater installed inside the seat activates by operating seat heater switch (7) on the optional equipment control switch panel.

When seat heater switch (7) is turned ON, the seat surface is heated so that the seat section becomes warm. When the temperature of the seat section is raised to the specified temperature, heating is automatically stopped.

NOTE: Depending on what kinds of optional equipments are installed, the switch button function may differ. Use the switch only after confirming the kinds of the installed optional equipment.

Armrest

M1G6-01-017

M1J1-03-001

M1U1-01-011

1-86

OPERATOR'S STATION

ADJUSTING THE AIR-SUSPENSION SEAT

(Optional)

Seat Height and Angle Adjustment

(1).

Use lever (1) to adjust the seat height and/or seat angle as follows:

• To adjust the front part of the seat:

Push down lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

• To adjust the rear part of the seat:

Pull up lever (1) while sitting on the seat, and apply or remove body weight to obtain the desired height. When the desired height is obtained, release lever (1).

Console and Seat Fore-aft Adjustment

Pull lever (2) to the right to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers. Release lever to lock seat and consoles into position.

NOTE: Seat and console fore-aft adjustment range is 120 mm

(4.8 in) with steps every 20 mm (0.8 in).

Seat Fore-Aft Adjustment

Pull lever (3) to unlock the seat from both consoles. With lever (3), slide the seat to the desired distance from pilot control levers. Release the lever.

NOTE: Seat fore-aft adjustment range is 160 mm (6.3 in) with steps every 16 mm (0.8 in).

Suspension Adjustment

Push knob (4) to increase suspension stiffness.

Pull knob (4) to decrease suspension stiffness.

Backrest Adjustment

Pull up lever (5) to release backrest lock. Move backrest to the desired position and release the lever.

Warning: Possibility of pinched fingers

Push down with the palm.

SS-955

M1U1-01-014

1-87

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).

SEAT WITH A BUILT-IN HEATER

Raise the armrest, the heater installed inside the seat activates by operating seat heater switch (8) on the optional equipment control switch panel.

When seat heater switch (8) is turned ON, the seat surface is heated so that the seat section becomes warm. When the temperature of the seat section is raised to the specified temperature, heating is automatically stopped.

NOTE: Depending on what kinds of optional equipments are installed, the switch button function may differ. Use the switch only after confirming the kinds of the installed optional equipment.

M1G6-01-017

Armrest

M1J1-03-001

M1U1-01-011

1-88

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.

Adjusting Procedures

1. Lower the bucket to the ground. Stop the engine.

2. Move the pilot control shut-off lever to the LOCK position.

3. Remove left and right console holding bolts (1). Loosen bolts (2) to adjust the console height.

4. After adjusting, tighten bolts (1) and (2).

Tightening Torque: 49N•m (5 kgf•m)

M1U1-01-030

1-89

OPERATOR'S STATION

SEAT BELT

WARNING: Be sure to use the seat belt when operating the machine.

Before operating the machine, be sure to examine seat belt (1), buckle (2), and attaching hardware. Replace seat belt (1), buckle (2), or attaching hardware if they are damaged, or worn.

Replace seat belt (1) every three years, regardless of appearance.

Seat Belt

1. Confirm that seat belt (1) is not twisted. Securely insert the end of seat belt (1) into buckle (2).

Lightly pull on the belt to confirm that the buckle latches securely.

2. Adjust seat belt (1) so that the belt is snug but comfortable.

3. Push button (3) on buckle (2) to unfasten seat belt (1).

2 1

M1U1-01-031

M1U1-01-037

M1U1-01-032

1-90

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. Avoid excess engine idling.

3. Check indicator lights and gauges frequently during operation.

EVERY 8 HOURS OR DAILY

1. Perform 8-hour or daily service. (See Maintenance guide

-- 8 hours.)

2. Watch for fluid leaks.

3. Lubricate working tool pivots every 8 hours for the first

50 hours, and every 8 hours when working in mud and water.

AFTER THE FIRST 50 HOURS

1. Perform 50-hour service. (See Maintenance guide -- 50 hours.)

2. Check accessible hardware torque. (See Hardware Torque

Specifications in Maintenance chapter.)

AFTER THE FIRST 100 HOURS

Perform 50-hour and 100-hour service. (See Maintenance

Guide -- 50 hours and 100 hours.)

2-1

BREAK-IN

2-2

OPERATING THE ENGINE

INSPECT MACHINE DAILY BEFORE STARTING

Bucket Cylinder

Link A

Arm

Arm Cylinder

Boom

Washer Tank

Swing Bearing

Center Joint

Battery

Tool Box • Electric Grease Gun •

Auto-Lubrication Device

Swing Device

Link B

Side Cutter

Boom Cylinder

Control Lever

Tooth

Reservoir

Fuel Tank

Control Valve

Fuel Filter

Radiator/Oil Cooler

Inter Cooler/Fuel Cooler

Counterweight

Cab

Front Idler

ELECTRICAL SYSTEM

Check for worn or frayed wires and loose connections.

Muﬄer

Track Adjuster

Track Frame

Hydraulic Tank

Lower Roller

Upper Roller

Pilot Filter

Pump Drain Filter

Air Cleaner

Travel Device

Fan Motor

Engine

Engine Oil Filter

Pump

Track Link

Shoe

Fan Pump

Track

M1J1-01-001

HYDRAULIC SYSTEM

Check for leaks, kinked hoses, and lines or hoses that rub against each other or other parts.

BOOM, BUCKET, SHEET METAL, TRACKS

Check for bent, broken or missing parts.

LUBRICATION

Check lubrication points on the Periodic Service

Chart.

HARDWARE

Check for loose or missing parts.

PROTECTIVE DEVICES

Check guards, fenders.

FUEL SYSTEM

Drain water and deposits from fuel tank.

SAFETY

Walk around machine to clear all bystanders/obstacles from machine area.

3-1

OPERATING THE ENGINE

BEFORE STARTING ENGINE

1. Confirm that pilot control shut-off lever (1) is in the LOCK position.

2. Confirm that all control levers are placed in neutral.

3. Adjust the seat to allow full pedal and control levers stroke with operator’s back against the backrest. Fasten the seat belt.

NOTE: Use a wet cloth when wiping dust off monitor or switch panels to prevent damaging the panel face.

Rubber is used on the switch parts. Take care not to tear the rubber-made parts with sharp-edged tool, such as a screwdriver.

LOCK Position

M1U1-01-025

M1J1-03-005

CAUTION:If the security lock screen is displayed when turn the key switch to 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

3-2

OPERATING THE ENGINE

LEVEL CHECK

1. Stop machine on firm and surface level ground

2. Turn key switch (1) to the ON position.

3. Raise the armrest, while press and hold engine oil / coolant level switch (2), engine oil level indicator (4) / coolant level indicator (5) are displayed on monitor (3).

Green indicator will light when engine oil /coolant level is adequate. Red indicator will light when engine oil level is inadequate for operation. Check engine oil / coolant level and replenish it if necessary.

When release engine oil / coolant level switch (2), engine oil level indicator (4) / coolant level indicator (5) are not displayed on monitor (3).

IMPORTANT: Prevent possible machine damage.

Check fluid levels individually.

The level check does not take the place of daily inspection at hydraulic oil level window, engine coolant reserve tank and engine oil level dipstick.

Armrest

M178-01-049

M1J1-03-001

M1J1-03-002

M1J1-03-003

3-3

OPERATING THE ENGINE

STARTING THE ENGINE IN ORDINARY TEMPERA-

TURE

1. Pull the pilot control shut-off lever (1) up to the LOCK position.

2. Turn engine control dial (3) to the slow idle position.

3. Sound horn to alert bystanders.

4. Insert key switch (2). Turn it ON position.

5. “Wait-screen (nothing is displayed)” is displayed on the monitor for 2 seconds. Regardless of the pilot control shut-off lever position, the engine can not be cranked during this duration.

6. When the password input screen is displayed on the monitor, input the password. 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.

7. The basic screen will be displayed on the monitor. Check that the preheat indicator (4) is OFF at this time.

8. Turn key switch (2) to start engine.

LOCK Position

Slow Idle

M178-01-049

IMPORTANT: Prevent starter damage.

Never operate starter motor for more than

10 seconds at a time. If engine fails to start, return key switch to OFF. Wait for more than

30 seconds, then try again. After a false start, do not turn key switch until engine stops or starter may be damaged.

9. Release key switch (2) immediately after the engine has started. It will return to ON position.

Password Input Screen

M1U1-01-025

M1U1-01-033

T1V5-05-01-002

3-4

Basic Screen

M1J1-03-004

OPERATING THE ENGINE

STARTING IN COLD WEATHER

Preheating

1. Pull the pilot control shut-off lever (1) up to the LOCK position.

2. Turn engine control dial (3) to around the middle between the L and H positions.

3. Sound horn to alert bystanders.

4. Insert key switch (2). Turn it ON position.

5. “Wait-screen (nothing is displayed)” is displayed on the monitor for 2 seconds. Regardless of the pilot control shut-off lever position, the engine can not be cranked during this duration.

6. When the password input screen is displayed on the monitor, input the password. 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.

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 indicator (4) is lit for automatically.

NOTE: In case, preheat indicator (4) does not come ON, preheating is not required.

8. As soon as preheat indicator (4) goes OFF, turn the key switch (2) to the START position to rotate the starter.

IMPORTANT: Prevent starter damage.

Never operate starter motor for more than

10 seconds at a time. If engine fails to start, return key switch to OFF. Wait for more than

30 seconds, then try again. After a false start, do not turn key switch until engine stops or starter may be damaged.

9. Release the key switch (2) immediately after the engine has started. It will return to ON position.

LOCK Position

Slow Idle

M178-01-049

Password Input Screen

M1U1-01-025

M1U1-01-033

T1V5-05-01-002

Basic Screen

M1J1-03-004

3-5

OPERATING THE ENGINE

CHECK INSTRUMENTS AFTER STARTING

Checking lnstruments through Monitor Functions.

After starting the engine, check the following points through the monitor functions.

Check that

1. Alternator indicator (1) is off.

2. Engine oil pressure indicator (2) is off.

3. Engine noise and exhaust gas are normal.

IMPORTANT: Prevent possible damage to engine. If indicator lights do not go out after starting engine, IMMEDIATELY STOP THE ENGINE and correct the cause.

Operate machine at less-than-normal loads and speeds until engine is at normal operating temperature.

M1J1-03-006

3-6

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. Explosion of the battery may result.

Park the machine on a dry, firm or concrete surface, not on steel plates, if the machine is parked on steel plates, dangerous sparks may be unexpectedly created on the machine.

Never connect a positive terminal to a negative terminal, as a dangerous short circuit will occur.

• The operator must be in the operator’s seat so that

the machine will be under control when the engine starts. Jump starting is a two-person operation.

IMPORTANT: The machine electrical system is a 24 volt negative (–) ground. Use only 24 volt booster batteries.

When the machine batteries are exhausted, start the engine using booster batteries as shown below.

Connecting the booster batteries

1. Stop the engine of the machine on which booster batteries are mounted.

2. Connect one end of red cable (1) to the positive (+) terminal of the machine batteries, and the other end to the positive (+) terminal of the booster batteries.

3. Connect one end of black cable (2) to the negative (–) terminal of the booster batteries, and then make ground connection to the frame of the machine to be started with the other end of black (–) cable (2). In the last connection to frame, be sure to connect the cable end as far away from the machine batteries as possible.

4. Start the engine of the machine on which booster batteries are mounted.

5. Start the engine of the troubling machine.

6. After the engine starts, disconnect cables (2) and (1), following the procedure below.

(Red)

SA-032

Booster Batteies Machine Batteies

(Black)

To Upperstructure of the Machine

Connecting the Booster Batteries

M104-03-002

3-7

OPERATING THE ENGINE

Disconnecting the booster batteries

1. Disconnect black negative (–) cable (2) from the machine 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.

4. Disconnect red positive (+) cable (1) from the machine batteries.

(Red)

Booster Batteies Machine Batteies

(Black)

To Upperstructure of the Machine

Connecting the Booster Batteries

M104-03-002

3-8

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 run the engine for 5 minuets to cool the engine.

IMPORTANT: Turbocharger may be damaged if the engine is not properly shut down.

4. Turn key switch (2) OFF. Remove the key from the key switch.

5. Pull pilot control shut-off lever (3) to the LOCK position.

If the engine does not stop with the key switch turned in the OFF position

In case the engine does not stop even if the key switch is turned OFF due to failure of the machine, move emergency stop switch (4) downward to stop the engine.

CAUTION: Do not use the emergency stop switch, except when unavoidable.

Moreover, Do not operate the machine until repair is completed when stopping the engine with the failure of the machine.

Slow Idle

SA-390

M1U1-01-025

M1U1-01-033

M178-01-049

M1U1-01-029

3-9

OPERATING THE ENGINE

3-10

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.

Select a route that is as flat as possible. Steer machine as straight as possible making small, gradual changes in direction.

When driving over rough terrain, reduce engine speed to lessen possibility of undercarriage damage.

NOTE: An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction.

Arrow-mark

M178-03-001

4-1

DRIVING THE MACHINE

STEERING THE MACHINE USING PEDALS

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. Be sure to confirm the position of the travel motors before traveling.

• FORWARD TRAVEL

Push down on front (A) of both pedals.

• REVERSE TRAVEL

Push down on rear (B) of both pedals.

• NEUTRAL POSITION (C)

When the travel pedals are placed in neutral, travel brakes automatically will stop and/or hold the machine.

• RIGHT TURN

Push down on front of left pedal.

• LEFT TURN

Push down on front of right pedal.

• SHORT TURN (Spin turn)

Push down the front of one pedal and the rear of the other.

Cab

NOTE: For long-term traveling, push down on pedal tabs (D) and rest feet on footrests.

Forward and Reverse

Front Idler

Travel Motor

M104-01-038

M104-04-009

M104-04-003

Pivot Turn

M104-04-010

M104-04-005

4-2

Spin Turn

M1J1-04-001

M104-04-007

DRIVING THE MACHINE

STEERING THE MACHINE USING LEVERS

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. Be sure to confirm the position of the travel motors before traveling.

• FORWARD TRAVEL

Push both levers forward (A).

• REVERSE TRAVEL

Pull both levers rearward (B).

• NEUTRAL POSITION (C)

When the travel levers are placed in neutral, travel brakes automatically will stop and/or hold the machine.

• RIGHT TURN

Push left lever forward.

• LEFT TURN

Push right lever forward.

• SHORT TURN (Spin turn)

Push one lever forward and pull the other rearward.

NOTE: For long-term traveling, push down on pedal tabs (D) and rest feet on footrests.

Cab

Forward and Reverse

Front Idler

Travel Motor

M104-01-038

M104-04-009

M104-04-003

Pivot Turn

M104-04-010

M104-04-005

4-3

Spin Turn

M1J1-04-001

M104-04-007

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.

Turn travel mode switch (1) on the switch panel to the specified position to select the travel mode (Fast/Slow).

• Fast Mode: Turn travel mode switch (1) to

mark (2) position.

• Slow Mode: Turn travel mode switch (1) to sition.

mark (3) po-

Mark (Fast Speed Mode)

Mark (Slow Speed Mode)

TRAVEL ALARM (Optional)

During travel operation, the travel alarm (4) sounds the buzzer to warn the people near the machine that the machine is traveling.

Deactivating Travel Alarm

More than 15 seconds after starting to travel the machine, raise the armrest and push the travel alarm deactivation switch (5) to stop the travel alarm. (Within 15 seconds, the travel alarm deactivation switch is inoperable.)

Once the machine stops traveling and when restarting to travel, the travel alarm will sound again. If desired to stop the alarm, operate the deactivation switch (5) once more.

NOTE: The optional switch locations differ depending on what kinds of optional devices are equipped. Before using the switches, make sure what kinds of optional devices are equipped.

M1U1-01-015

M162-01-016

Armrest

M1J1-03-001

M1U1-01-035

4-4

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.

• Swing the upperstructure 90° and lower the bucket to raise one track off the ground. Make sure to keep the angle between the boom and arm 90 to 110° and position the bucket’s round side on the ground.

• Rotate the raised track back and forth to remove mud and dirt.

• After lowering the track to the ground, select slow travel speed. Carefully move the machine to firm ground.

• Utilize the boom and arm functions to pull the machine toward firm ground.

• Tow the machine if the machine becomes stuck but only if the engine is still operating. Be sure to attach a tow line correctly. (Refer to the “TOWING MACHINE A SHORT DIS-

TANCE” section on the next page.)

NOTE: When raising the machine off the ground with the front attachment, turn the boom mode switch OFF.

RAISE ONE TRACK USING BOOM AND ARM

WARNING: Keep the angle between boom and arm 90 to 110° and position the bucket’s round side on the ground.

Swing the upperstructure 90° and lower the bucket to raise track off ground. Do not dig bucket teeth into the ground when using the hoe bucket reversed.

Place blocks under machine frame to support the machine.

IMPORTANT: When the machine is modified as a face shovel by installing the hoe bucket in reverse, avoid raising the machine above the ground using the front attachment with the bucket cylinder fully extended. Excessive loads will be applied to the pins around the bucket and the bucket cylinder, resulting in breakage of the pins.

WRONG

90 to 110˚

M104-05-012

M104-05-013

SA-817

4-5

DRIVING THE MACHINE

TOWING MACHINE A SHORT DISTANCE

CAUTION:

• Cables, straps, or ropes can break causing serious 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.

• Be sure to check that the travel mode switch is in the TURTLE position.

• Be sure to turn the auto idle/acceleration switch

OFF.

• Always slowly drive the machine.

• Do not apply shock loads to the towing rope.

• Never allow anyone to enter between the towing machine and the towed machine while towing.

When your machine becomes struck but the engine is still operational, attach wire rope tow lines as illustrated at right, and slowly tow your machine to firm ground using another machine.

Be sure to attach the wire ropes around the track frames of both machines as illustrated.

To prevent the wire ropes from being damaged, place some protective material between the track frame and the wire ropes.

(ZAXIS450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

)

Max. Traction Force: 319 kN (32500 kgf, 71700 lbf)

(ZAXIS500LC

-3

, 520LCH

-3

)

Max. Traction Force: 415 kN (42300 kgf, 93300 lbf)

IMPORTANT: • Atach a wire tow line around the machine frame as shown to the frame shackle hole using a suitable clevis.

• Slowly tow, keeping the tow line horizontal and in a straight line with the tracks.

• When the machine is towed, release parking brakes by operating the travel levers.

Soft

Protecort

Wire Rope

Shackle

M1U1-05-001

4-6

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.

When operating in such conditions, check the machine’s position often. Reposition the machine if necessary.

Avoid submerging the swing bearing, swing gears and center joint.

If the swing bearing, swing gears and center joint are submerged, remove the drain plug to drain mud and water. Clean swing area. Install plug. Lubricate swing internal gear and swing bearing.

Swing Internal Gear Capacity: 16 to 18 liter (4.2 to 4.8 US gal)

Lubricate swing bearing. (See Maintenance Guide, 500 hours)

Model

ZAXIS450

-3

ZAXIS470H

-3

ZAXIS450LC

-3

ZAXIS470LCH

-3

ZAXIS500LC

-3

ZAXIS520LCH

-3

1050 mm (41 in)

M104-05-009

1120 mm (44 in)

4-7

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.

• Return the control levers to neutral and pull the pilot control shut-off lever to the LOCK position.

• Block both tracks.

M104-05-014

PARKING THE MACHINE

1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if the engine is not properly shut down.

4. Turn engine control dial (1) counterclockwise to the stop

(the slow idle position).

Run the engine approximately 5 minutes to cool the engine.

5. Turn the key switch to OFF. Remove the key from the key switch.

6. Pull pilot control shut-off lever (2) to the LOCK position.

IMPORTANT: Protect cab electrical components from bad weather. Always close windows, roof vent and cab door when parking the machine.

7. Close windows, roof vent, and cab door.

8. Lock all access doors and compartments.

Slow Idle

Lock Position

M1U1-01-033

M1U1-01-025

4-8

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.

Prevent possible injury from unexpected machine movement.

Make sure you know the location and function of each control before operating.

The machine is equipped with a label showing the control patterns of the levers and pedals.

IMPORTANT: When digging, avoid hitting tracks with boom cylinders.

When digging over the end of the tracks, travel motors should be at the rear to maximize machine stability and lift capacity.

When a lever is released, it will automatically return to neutral, and that machine function will stop.

1- Arm Roll-Out

2- Arm Roll-In

3- Swing Right

4- Swing Left

5- Boom Lower

6- Boom Raise

7- Bucket Roll-In.

8- Bucket Roll-Out.

M1J1-01-022

M104-05-001

8 7

M104-05-002

5-1

OPERATING THE MACHINE

CONTROL LEVER (HITACHI PATTERN)

Prevent possible injury from unexpected machine movement.

Make sure you know the location and function of each control before operating.

The machine is equipped with a label showing the control patterns of the levers and pedals.

IMPORTANT: When digging, avoid hitting tracks with boom cylinders.

When digging over the end of the tracks, travel motors should be at the rear to maximize machine stability and lift capacity.

When a lever is released, it will automatically return to neutral, and that machine function will stop.

1- Swing Right

2- Swing Left

3- Arm Roll-In

4- Arm Roll-Out

5- Boom Lower

6- Boom Raise

7- Bucket Roll-In.

8- Bucket Roll-Out.

M1J1-01-022

M104-05-001

8 7

M104-05-002

5-2

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. The pilot control shut-off function will not be activated otherwise.

• When leaving the machine:

• Stop the engine.

• Then, pull the pilot control shut-off lever up to the

LOCK position.

• Always check to be sure that the pilot control lever is pulled up to the LOCK position before:

• Transporting the machine.

• Leaving the machine at the end of the shift.

Pilot Control Shut-Off Lever Operation

Before Leaving the Machine:

1. Park the machine on a firm, level surface. Lower the bucket to the ground. Return all control levers to neutral.

Properly shut down the engine.

2. Pull pilot control shut-off lever (1) up into the full LOCK position.

Before Starting Operation:

1. Confirm that pilot control shut-off lever (1) is pulled up to the LOCK position.

After starting the engine:

1. Confirm that all control levers and pedals are in neutral and that no part of the machine is in motion.

2. Lower pilot control shut-off lever (1) to the UNLOCK position.

If any part of the machine (any actuator) moves when the pilot control shut-off lever is lowered to the UNLOCK position despite the fact that all controls are placed in neutral, the machine is malfuntioning. Immediately pull the pilot control shut-off lever back to the LOCK position, and stop the engine. Then, see your authorized dealer.

LOCK Position

UNLOCK Position

M1U1-01-025

M1U1-01-024

5-3

OPERATING THE MACHINE

Warming-up Operation

Warm up the engine coolant as follows:

1. Run the engine with engine control dial (1) turned to the slow idle position.

Slow Idle

M1U1-01-033

Hydraulic Oil Warm-Up Operation

IMPORTANT: Hydraulic components may be seriously damaged if the machine is operated with hydraulic oil temperature below 30°C (86°F).

Always warm hydraulic oil to specifications before operating the machine.

In case the hydraulic oil temperature is lower than 0 °C when starting the engine, the engine speed is automatically increased for approx. 12 minutes to quickly warm up the hydraulic oil.

NOTE: As soon as the hydraulic oil is warmed upto 0 °C even though it is still shorter than 12 minutes, the warm-up operation is automatically complete so that the engine runs at an idle speed.

During auto warm-up operation, if the engine speed is increased more than that of the auto warm-up operation by operating engine control dial (1), the engine runs at the speed set by engine control dial (1).

M1J1-05-001

5-4

OPERATING THE MACHINE

Warming-up the Motor and the Cylinders

IMPORTANT: • In cold weather, be sure to thoroughly warm-up the motors and cylinders.

• If the hydraulic circuit is continuously relieved for a certain amount of time, the temperature in the control valve would rise excessively. Never operate to stroke end more than 15 seconds. After relieving any function, up to 15 seconds, be sure to have a 5–10 second intermission.

1. Check that the needle of coolant temperature gauge (2) starts moving so that engine coolant warm-up operation is complete.

2. Turn engine control dial (1) to the medium position.

3. Operate the boom, arm and bucket cylinders slowly to each stroke end several times.

4. Operate travel and swing functions slowly, initially moving only short distances.

5. Continue to repeat steps 3 and 4 until bucket cycle time is normal.

M1U1-01-033

M1J1-05-001

5-5

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.

• Note that the auto-idle function will be deactivated if engine control dial (1) is operated while the engine is running at the auto-idle setting.

• Before stopping the engine, always turn engine control dial (1) counterclockwise to the stop (to the slow idle setting). Run the engine five minutes to cool the engine.

Then, turn key switch to OFF position to stop the engine.

Slow Idle

M1V1-01-001

High Idle

M1U1-01-033

5-6

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.

IMPORTANT: • Always check if auto-idle indicator (1) is turned on or off before starting operation.

If the indicator is on, the auto-idle function will be activated.

• Always be aware of engine control dial setting when auto-idle selector (3) turned to the A/I ON position. If the engine speed is set high with engine control dial (2), and if the operator is not aware of the high engine speed setting, the engine speed will unexpectedly increase when any control lever is operated, causing unexpected machine movement, thus possibly resulting in serious personal injury.

WARNING: Prevent the machine from unexpected movement. Be sure to turn off auto-idle selector (3) when unexpected machine movement is undesirable, especially when loading/unloading the machine for transportation.

Note that auto-idle function can be turned on or off only when the key switch is in ON position. Always check if the auto-idle function is turned on or off with auto-idle indicator (1).

Auto-Idle Function ON :

Auto-Idle Function OFF :

Auto-Idle Indicator (1) ON

Auto-Idle Indicator (1) OFF

• When auto-idle selector (3) is turned OFF with auto-idle indicator (1) ON, indicator (1) will go OFF and the autoidle system is deactivated.

• Even if the engine is stopped by turning the key switch with auto-idle selector (3) in the A/I ON position [indicator

(1) ON], the auto-idle system is not deactivated. When the engine is restarted, the auto-idle system remains activated, allowing auto-idle indicator (1) to flash for 5 seconds and stay ON later.

M1J1-05-001

M1V1-01-001

5-7

OPERATING THE MACHINE

WORK MODE

Five work modes can be selected for most appropriate front and swing speeds for the work to be performed.

When the engine is started, the digging mode is automatically set. Each time work mode switch is pressed, the four following modes are selected alternately.

• Digging Mode

• Breaker 1

• Breaker 2

• Breaker 3

The selected work mode is indicated by attachment mode indicator (2) of basic screen (1). Select the work mode corresponding to the work in which the machine is engaged while referring to the table below.

M1J1-05-001

Work Mode

Digging Mode

Description

Designed for general digging and truck loading.

Breaker 1 Mode✽1 (Initial Setting Flow Rate 200L/min)

Breaker 2 Mode✽1 (Initial Setting Flow Rate 250L/min)

Breaker 3 Mode✽1 (Initial Setting Flow Rate 280L/min)

Select this mode switch when using MITSUBISHI MKB2550V, FU-

RUKAWA F-30, F-35 or OKADA TOP 300 respectively.

Select this mode switch when using NPK E-220, FURUKAWA

F-45, MITSUBISHI MKB300V or OKADA OUB 324 respectively.

Select this mode switch when using HITACHI HSB90S, NPK E-225,

OKADA OUB 330, 524 or MITSUBISHI MKB4000V respectively.

✽

1 When using hydraulic crusher, select the breaker mode 1, 2, or 3 when the flow rate of the crusher corresponds to the breaker mode 1, 2, or 3.

NOTE: Four work modes shown above are designated as the standard specifications. Up to three 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.

When using hydraulic breaker or crusher, if required setting flow rate is insufficient, see your nearest authorized dealer for correct information.

As for the machine equipped with the flow combined piping, switch the flow combining valve to the suitable position for the usage. (Refer to the flow combining valve operation of Chapter 13 in detail.)

M1J5-01-011

5-8

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). Then, press determination key (6).

M1J1-05-001

M1J5-05-002

M1J5-05-003

5-9

OPERATING THE MACHINE

POWER BOOST

The power boost switch (4) is used to gain maximum digging power, and is located on the top of the right control lever.

When the power boost switch (4) is pushed, increased front attachment power will be supplied for about 8 seconds.

M1J1-01-024

5-10

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. Although production is reduced slightly more than in the P mode, the fuel consumption and noise levels are reduced, allowing the machine to operate most efficiently.

• P Mode

Operate the machine in this mode when performing normal work.

• H/P (High Power) Mode

WARNING: In the H/P mode, the engine speed will change quickly. To ensure safety, be sure to turn power mode switch (1) to the P or E mode position before starting such works as loading the machine on or off a trailer or lifting a load with the front attachment, which may result in personal accidents if the engine speed is suddenly changed.

When rolling in the arm while digging deep trenches for example, more power may be required. In such cases, use the H/P mode. The maximum power of the machine can be utilized in this mode, increasing work efficiency when more power is required than in the P mode.

The H/P mode is activated and the engine speed is increased when the boom raise or the arm rolled-in operation is made with the engine fast idle speed set at 1650 min

-1

50.

NOTE: In the H/P mode, the engine speed changes depending on load applied to the machine.

5-11

M1U1-01-015

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. When soil sticks to the bucket, remove it by moving the arm and/or bucket rapidly back and forth.

4. When trenching a straight line, position the tracks parallel to the trench. After digging to the desired depth, move the machine as required to continue the trench.

IMPORTANT: When lowering the boom, avoid sudden stops that may cause shock load damage to the machine.

When operating the arm, avoid bottoming the cylinder to prevent cylinder damage.

When digging at an angle, avoid striking the tracks with the bucket teeth.

When digging a deep excavation, avoid striking the boom or bucket cylinder hoses against the ground.

GRADING OPERATION

WARNING: Do not pull or push dirt with the bucket when traveling.

Select grading mode when finishing work is required.

Position the arm slightly forward of the vertical position with bucket rolled back, as shown.

Operate arm roll-in function while slowly raising the boom.

Once the arm moves past, the vertical position slowly lower the boom to allow the bucket to maintain a smooth surface.

Grading operation can be more precisely done by operating the boom, arm and bucket simultaneously.

M107-05-037

M104-05-017

5-12

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 rollin/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.

AVOID ABUSIVE OPERATION

WARNING:Do not use travel as an additional digging force. Severe machine damage may result.

Do not raise rear of machine to use the machine’s weight as additional digging force. Severe machine damage may result.

M111-05-002

WRONG

M104-05-018

5-13

OPERATING THE MACHINE

OPERATING TIPS

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 (the bucket completely curled under).

Adjust the length and depth of each cut to produce a full bucket with every pass.

Full loads on every pass is more productive than a faster cycle with a partially filled bucket.

Full load should be the first objective, followed by speed, to increase productivity.

WARNING: Do not attempt to break ledge rock by extending the arm to maximum reach and dropping the front of the bucket on the bucket teeth for penetration. Serious damage to the machine can result.

Once the trench is open, ledge rock can be broken by pulling the bucket up under the layers. The top layers are pulled out first, with one or two layers being lifted at a time.

Do not side load the bucket. For example, do not swing the bucket to level material or do not strike objects from the side with the bucket.

SELECT CORRECT TRACK SHOES

IMPORTANT: Using wide track shoes on rough ground may result in shoe bending and/or loosening, and may damage other undercarriage components.

Never use wide track shoes on rough ground such as rocks, sand or gravel. Wide track shoes are designed for soft ground.

Track shoe bolts should be checked periodically for tightness.

WRONG

M104-05-019

WRONG

M161-05-006

5-14

OPERATING THE MACHINE

OBJECT HANDLING --- IF EQUIPPED

WARNING: When using machine for object handling operation, be sure to comply with EN 474-5, which prescribes that the machine must be equipped with the rated lifting-load table, lifting hook, overload alarm device, and hoserupture safety valve when applied to object handling.

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.

Never move the load suddenly. Never move load over a person’s head. Do not allow any persons near load.

Keep all persons away from raised load until blocks are supporting it or load is sitting on the ground.

Position upperstructure so that the travel motors are at the rear.

Do not attach sling/chain to the bucket teeth.

Be sure that the maximum lifting load does not exceed the rated load as shown in the lifting load table plate or operator’s manual.

The overload alarm device warns the operator with a buzzer sound when the lifting load exceeds the lifting capacity. If the buzzer sounds, immediately move the load into the safety range, or lower the load on the ground.

Be sure to turn the overload alarm device switch ON while the machine is used for object handling.

When the machine specifications are modified from the original specifications of the machine delivered, for example, changing the front attachment or track shoes, changing or new installing the overload alarm device may be require. Be sure to consult your authorized Hitachi dealer.

Check that the specifications of the front and machine to be used meet the specifications shown on the rated lifting load table. If any discrepancies between them are found, replace the rated lifting load table so that no discrepancy is found.

Rated lifting load table

M1J1-03-001

SA-014

M1U1-05-004

M1U1-01-010

5-15

OPERATING THE MACHINE

1. Secure sling/chain tightly to the load being lifted. Wear gloves when securing sling/chain.

2. Fasten sling/chain to bucket loop, with the bucket curled and arm retracted.

3. Coordinate hand signals with your signal man before starting.

4. Be aware of the location of all persons in the working area.

5. Attach a hand line to load and make sure person holding it is well away from load.

6. Before lifting, test your load.

• Park your machine close to load.

• Attach load to the machine.

• Raise load 50 mm above the ground.

• Swing the load all the way to one side.

• While keeping load close to the ground, move it away from machine.

• If there is any indication of reduced stability of your machine, lower load to the ground.

7. Lift load only as high as necessary.

5-16

OPERATING THE MACHINE

OVERNIGHT STORAGE INSTRUCTIONS

1. After finishing the day’s operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods.

Park the machine referring to the “PARKING THE MA-

CHINE” in the “DRIVING THE MACHINE” section.

2. Fill the fuel tank with fuel.

3. Clean the machine.

4. If anti-freeze or long life coolant is not used in cold weather, be sure to drain coolant from the radiator and the engine jacket. Also, be sure to put a tag in a visible place if the coolant has been drained.

M1J5-05-004

5-17

OPERATING THE MACHINE

5-18

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.

• Coordinating Signal System, and Appointing Signal Person

Before starting, be sure to coordinate the signal system to be used.

Appoint one qualified signal person (if a multiple number of signal persons are used, different signals may confuse the workers, possibly causing an accident). All workers should obey the signals only from one signal person.

• Secure flat space more than 10 m (11 yd) square enough to assemble the machine.

• Check that footing is strong enough to support the machine weight. If required, repair the footing sufficiently so that the machine can be kept in a horizontal position.

• Assembly work may cause the potential for personal injury.

Before starting, be sure to prepare completely, including arranging all necessary tools. Never fail to prepare the following equipment and tools.

Essential Equipments and Tools

• A 25-ton class lifting capacity crane

• Wire ropes to sling the machine

• Shackles

• Slinging protectors (Soft Pads)

• 100 mm (4 in) square lumber

• 10 pound hammer

• Standard tools

• Grease

6-1

ASSEMBLING

• Bolt Tightening Torque Specifications

Bolt Location

Bolt

Size N•m

Counterweight mounting bolt

Counterweight lock plate securing bolt

M45

M24

Pin lock securing bolt M20

2400

450

400

Hose connecting bolt

M12

M14

110

180

Torque

(kgf•m) (lbf•ft)

(240) (1735)

(45)

(40)

(10)

(18)

(325)

(290)

(70)

(130)

• Precautions for Tightening Bolts

Use a torque wrench to tighten bolts to specifications. After tightening bolts to specification, mark the tightened bolt head to ensure that all the bolts have been tightened.

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

6-2

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). All workers should obey signals only from one signal person.

• When attaching a wire rope to the lifting

parts/components, always use slinging protectors between the wire rope and the lifting parts/components to prevent damage.

• Precautions for Lifting

• Always use a hook with a latch.

• Use only slinging wire ropes and chains that are strong enough.

• Never allow the lifted load to pass over any persons.

• Never allow anyone under the lifted load.

• Rectifying Twisted Wire Rope

Rectify the twist or bend of the wire ropes after the work.

Store the wire ropes in a specified place.

M324-07-171

M324-07-173

M324-07-174

6-3

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. Use the horn or other signals to warn the bystanders.

• If visual sight is obstructed, be sure to use a signal/guide person. Always keep the signal/guide person in view.

• Thoroughly learn and coordinate the meanings of all signs and signals. Appoint one qualified signal/guide person.

• Keep bystanders or obstructions away from the operating area of the machine.

• Driving the Machine Safely

• Always be alert for the safety of bystanders.

• Before driving the machine, find out which way to move the travel levers for the direction you want to drive the machine.

• Avoid Injury from Back-Over and Swing Accident

During swing or backing up operation, operator’s visual sight is obstructed, leading to a potential accident. If visual sight is obstructed, used a signal/guide person.

• Always check that everyone is kept away from the operating area of the machine before swinging or backing up the machine.

• Use the horn or signals to warn bystanders not to enter into the operating area of the machine.

6-4

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). Install two bolts (10), each two washers (8) (9), two nuts (7) and shim (6). Tighten counterweight mounting bolts (10) by power wrench.

Tightening torque: 2400 N•m (240 kgf•m, 1735 lbf•ft)

4. Install shims (4), (5), plates (3), lock washers (2), and bolts

(1).

Tightening torque: 450 N•m (45 kgf•m, 325 lbf•ft)

NOTE: If any gap exists between plates (3) and bracket, fill the gap with shims (4), (5).

5. Install covers (11), (12) with each 11 pieces of spring washers (14) and washers (15). Tighten bolts (13).

Counter Weight

W1J1-02-02-001

W1J1-02-02-002

1, 2

4, 5

Bracket

Convex Bosses

M1J1-06-016

6-5

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 the boom foot pin (2) until the end of the pin is flush with the inside end of the bracket.

2. Apply a film of grease to pin (2).

3. Lift up left-hand boom cylinder (3) with a crane.

WARNING:

• When aligning the centers of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• When inserting the pin, never enter into the area under the boom cylinder.

4. Align the boom cylinder bottom hole with the boss hole on the frame. Measure clearance “a.” If clearance “a” is 4 mm (0.16 in) or more, remove the shim on the pin and install it , as illustrated.

5. Align pin hole (4) on the bottom side of the boom cylinder with pin hole (5) on the main frame to drive pin (2) in.

Take care not to damage the seal at this time.

6. Tighten bolt (6) to secure pin lock plate (1).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

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.

Boss of Main

Frame Side

Clearance (a)

Bracket

Shim

Bracket

M116-07-025

Boss of Bottom Side of Boom Cylinder

M1J1-06-017

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 securing the covers to the ends of the hydraulic piping on the machine to release the trapped oil pressure in the piping.

9. Gradually loosen bolts securing the covers to the ends of the hydraulic piping on the machine to release the trapped oil pressure in the piping. Then, remove the covers.

5 4

M116-07-026

6 1

M116-07-027

6-6

ASSEMBLING

10. Connect four hoses between both the right and left boom cylinders and the machine.

Tightening torque: 180 N•m (18kgf•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.

(2) Slowly extend or retract boom cylinder rod (8).

(3) Repeat the same operation of the step 2 above until cylinder rod (8) moves smoothly.

M116-07-028

6-7

ASSEMBLING

INSTALLING BOOM

WARNING: Never allow anyone to enter into the area under a lifted boom (2).

1. Pull out the boom foot pin (1) until the end of the pin is flush with the inside end of the right side bracket.

2. Apply a film of grease to pin (1).

3. Lift up boom (2) with a crane.

NOTE: Connect a chain block to one side wire rope (3) to adjust the wire rope length to position the boom easily.

4. Make a mark appointing the outer fringe of the boom foot boss on the inside surface of the boom mounting bracket of the mainframe, so that the boom can be easily installed on the mainframe.

WARNING:

• When aligning the center of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• When inserting the pin, never enter into the area under the boom.

5. Align the boom bottom hole with the boss hole on the frame. Measure clearance “a.” If clearance “a” is 1 mm or more, remove the shim on the pin and install it on the cab side, as illustrated

6. Push boom foot pin (1) in. (Refrain from driving the pin in with a hammer if possible. The pin can be easily inserted by hand if alignment, of the pin and pin hole, is correct.)

7. Secure boom foot pin (1) with plate (5) and bolts (6).

Bolt tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

8. Lower the boom tip to the ground.

Bracket

Boss of

Frame Side

Mark

Clearance (a)

Boss of Boom Foot

Shim

M116-07-113

M116-07-036

Cab Side

M1J1-06-018

6-8

M116-07-121

M116-07-030

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.

Frame

1. Gradually loosen bolts securing the covers to the ends of the hydraulic piping on the machine to release the trapped oil pressure in the piping. Then, remove the covers.

2. Connect four hoses between both the right and left boom cylinders and the machine.

3. Check that hose (1) does not come into contact with the area on the frame. Hose (1) may come into contact with the swing device when the boom cylinder is extended most

M1J7-06-002

6-9

ASSEMBLING

INSTALLING BOOM CYLINDER ROD

1. Sling right-hand boom cylinder (3) with a crane.

2. Align the rod-pin bore of the boom cylinder (3) with that of boom (2) by moving the boom cylinder up and down while extending or retracting cylinder rod (1).

WARNING:

• When aligning the centers of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• When inserting the pin, never enter into the area under the boom cylinder rod.

3. After driving pin(4) into the pin bore, install pin lock plate

(5) onto the right end (the side to which the cylinder rod has been installed) of the pin with bolts (6).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

4. Slide pin (4) to the right side (the side to which the cylinder rod has been installed) to allow the left side boom cylinder rod to be in the position ready for installation.

5. Install the left-hand boom cylinder rod in the same procedure used in the steps 2 to 3.

M116-07-033

M116-07-021

M116-07-022

6-10

ASSEMBLING

INSTALLING ARM

WARNING: Never allow anyone to enter into the area under the lifted arm (2).

1. Apply grease to boom (1) and arm (2) connecting pin (3).

2. While slinging arm (2) with a crane, align pin hole (4) of arm (2) with that of boom (1).

3. Install the plate between boom (1) and arm (2). Align the boom (1) bottom hole with the boss hole on the arm (2).

Measure clearance “a.” If clearance “a” is 1 mm (0.04 in) or more, remove the shim on the pin and install it, as illustrated

WARNING:

• When aligning the centers of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• When inserting the pin, never enter into the area under the arm.

4. Drive the pin into the arm and boom holes.

5. Insert pin lock plate (5) with bolts (6).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

Shim

M1J1-06-019

M1J1-06-020

Clearance (a)

M1J1-06-021

6-11

ASSEMBLING

CONNECTING ARM CYLINDER ROD

1. To prevent seals from damage, bleed the air from the arm cylinder according to the following procedures.

(1) Start the engine and run it at slow speed.

(2) Sling arm cylinder (2) with a crane. Slowly extend and retract rod (1).

(3) Repeat operation in step 2 until cylinder rod (1) moves smoothly.

2. Align rod-pin bore (3) of the arm cylinder (2) with pin (4) on the arm by moving the arm cylinder (2) up and down while extending or retracting the cylinder rod.

WARNING:

• When aligning the centers of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• When inserting the pin, never enter into the area under the arm cylinder.

3. After driving the pin into the pin holes, install pin lock plate (5) with bolts (6).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

4. When connecting the arm-cylinder-rod greasing hose to the arm cylinder rod, install adaptor (7) with angle (A) of 10 to 30° so that the hose does not come into contact with the arm cylinder mounting bracket.

M167-07-017

M1J1-06-022

M1J1-06-020

M1J1-06-023

6-12

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 pipings. Then, remove the covers.

1. Gradually loosen bolts securing the covers to the ends of the hydraulic pipings on the boom to release the trapped oil pressure in the pipings. Then, remove the covers.

2. Connect two hoses between the hydraulic pipings on the boom and bucket cylinder.

3. To prevent seals from damage, bleed the air from the bucket cylinder according to the following procedures.

(1) Start the engine and run it at slow speed.

(2) Slowly extend and retract cylinder rod (1).

(3) Repeat operation in step 2 until cylinder rod (1) moves smoothly.

M167-07-018

6-13

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.)

2. Start the engine. Raise the arm (2) tip approximately 2.5 m (2.7 yd) above the ground.

3. Sling bucket (6) with a crane. Align pin (5) hole of the bucket with pin hole (4) of the arm.

4. While the top of the bucket boss contacts the arm, adjust the clearance between arm and bucket to become from

0.5mm to 1mm (0.02 in to 0.04 in) by Shims. Refer to the page for “Adjust the Bucket Linkage” in the maintenance section.)

Bucket Boss

WARNING:

• When aligning the centers of the pin and pin hole, never put fingers into the pin hole.

• When using a hammer, wear safety equipment such as safety glasses or a hard hat to protect against injury from flying pieces of metal.

• While installing the bucket pin, never allow anyone to enter into the area under the bucket.

5. Drive pin (5) into the pin bosses. Secure pin (5) with bolt

(8) and nuts (9).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

6. While extending or retracting the bucket cylinder, align pin hole (3) of the link with that of bucket (6).

7. Drive the pin (7) into the bucket and link. Secure the pin with bolt (10) and nuts (11).

Tightening torque: 400 N•m (40 kgf•m, 290 lbf•ft)

8. Slide the O-ring onto the boss end gap between the bucket and arm. (Refer to the page for “Change Bucket ” in the maintenance section.)

Clearance Adjust Part

Bucket

Shim

Arm

M1J1-06-024

M116-07-038

M503-07-056

M1J1-07-072

M116-07-039

6-14

ASSEMBLING

FINAL INSPECTION

WARNING:

• Air may be trapped in the hydraulic circuit after assembling. Avoid excessively quick operation to prevent the hydraulic components from damage.

• Bleed the air trapped in the hydraulic circuit by operating each cylinder several times. (Refer to the page for “Change Hydraulic Oil” in the maintenance section.)

1. Check that no oil leaks from each cylinder, piping, and hose, and that all bolts are securely tightened.

2. Check that the following pin locks are securely tightened.

• Boom foot pin

• Boom cylinder rod and bottom pins

• Boom and arm joint pin

• Arm cylinder rod pin

• Bucket cylinder rod pin

• Bucket and link joint pins

3. Check hydraulic oil level in the hydraulic oil tank. (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.

6-15

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.

• Investigate beforehand the conditions of the route to be traveled, such as dimensional limits, weight limits, and traffic regulations.

In some cases, disassemble the machine to bring it within dimensional limits or weight limits of local regulations.

TRANSPORTING THE MACHINE BY TRAILER

When using a trailer, the machine can be transported as one unit. Provide an appropriate trailer, referring to the dimensions of the machine in the transport position, as shown in the

Transporting section.

As for the ZAXIS600 excavator, be sure to retract the side frame before loading the machine onto trailer bed for transportation.

(Refer to the section for “Extension and contraction of track frame” in this section.)

LOADING/UNLOADING ON A TRAILER

Always load and unload the machine on a firm, level surface.

WARNING: Be sure to use a loading dock or a ramp for loading/unloading.

Ramp/Loading Dock:

1. Before loading, thoroughly clean the ramp and flatbed.

Dirty ramps or flatbeds with oil, mud, or ice on them are slippery and dangerous.

2. Place blocks against the truck and trailer wheels while using a ramp or loading dock.

3. Ramps must be sufficient in width, length, and strength.

Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength to support the machine and have an incline of less than

15 degrees.

6-16

M111-06-029

TRANSPORTING

Loading/Unloading

WARNING:

• Always turn the auto-idle/acceleration switch OFF and power mode switch (E) or (P) when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever.

• Always select the medium or slow speed mode with the travel mode switch.

• NEVER steer while driving up or down a ramp as it is extremely dangerous. If repositioning is necessary, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.

• The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

• Prevent possible injury from machine tipping while the upperstructure is rotating. Keep the arm tucked under and rotate the upperstructure slowly for best stability.

Loading

1. The machine direction should be as follows:

With the front attachment: Travel forward with the front attachment at the front.

Without the front attachment: Travel in reverse, as illustrated.

2. The centerline of the machine should be over the centerline of the trailer.

3. Drive the machine onto the ramp slowly.

With the front attachment:

• Position the tip of arm with its flat surface resting on the trailer. Angle of the arm to boom should be 90 to

110°.

• Rest the tip of arm on the trailer just before the machine begins to tip forward onto the trailer. Slowly travel forward until the tracks are firmly on the trailer.

• Slightly raise the arm. Keeping the arm tucked under, slowly rotate the upperstructure 180°.

Without the front attachment:

• Slowly rotate the upperstructure 180°.

• Lower the tip of arm onto blocks.

90 to 110°

Less than 15°

M111-06-032

M111-06-033

M111-06-029

6-17

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.

NOTE: In cold weather, be sure to warm up the machine before loading or unloading it.

Transporting

WARNING: Fasten chains or cables to the machine frame. Do not place chains or cables over or against the hydraulic lines or hoses.

1. Place blocks in front of and behind the tracks.

2. Fasten each corner of the machine and front attachment to the trailer with a chain or cable.

M1V1-06-001

6-18

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.

1. To move the machine over end of the trailer onto the ramp, rest the flat surface of the tip of arm on the ground.

Angle of the arm to the boom should be 90 to 110°.

IMPORTANT: Prevent possible damage to the hydraulic cylinders. Do not allow the machine to hit the ground hard with the arm.

2. The tip of arm must be on the ground before the machine begins to tip forward.

3. As the machine moves forward, raise the boom and extend the arm until the machine is completely off the ramp.

90 to 110°

M111-06-034

M111-06-035

6-19

TRANSPORTING

ZAXIS450

-3

(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.

Weight: 45700 kg (100750 lb)

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 10”)

4900

(16’ 1”)

A mm (ft•in)

12000

(39’ 4”)

11910

(39’ 1”)

11910

(39’ 1”)

11900

(39’ 1”)

B mm (ft•in)

3600

(11’ 10”)

3480

(11’ 5”)

3500

(11’ 6”)

4550

(14’ 11”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

45700

(100750)

46400

(102300)

NOTE: ** Removed the radiator front duct and cab handrail.

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150mm (6”)

515 mm

(20")

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425mm (17”)

M1J1-06-001

2340 mm (7'8")

1700 mm (5'7")

515 mm

(20")

M1J1-06-002

750 mm

(30")

1700 mm (5'7")

M1J1-06-003

6-20

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine

Weight: 32400 kg (69900 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’4”)

(Extended/Retracted)

Weight kg (lb)

32400

(69900)

33200

(71400)

(Extended/Retracted)

NOTE: ** Removed the radiator front duct and cab handrail.

Arm, Bucket

Arm Length mm (ft•in)

2900

(9’6”)

3400

(11’2”)

3900

(12’10”)

4900

(16’1”)

Bucket Capacity

(PCSA heaped) m

(yd

)

2.1

(2.7)

1.9

(2.5)

1.6

(2.1)

1.4

(1.8)

A mm (ft•in)

6010

(19’9”)

6430

(21’1”)

6930

(22’9”)

7760

(25’6”)

B mm (ft•in)

1270

(4’2”)

1270

(4’2”)

1270

(4’2”)

1170

(3’1”)

Max.

Width mm (ft•in)

1630

(5’4”)

1540

(5’1”)

1360

(4’6”)

1410

(4’8”)

Weight kg (lb)

4050

(8900)

3920

(8640)

4120

(9080)

3720

(8200)

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

515 mm

(20”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425mm (17”)

9860 mm (32’ 4”)

2960 mm (9’ 9”)

2340 mm (7’ 8”)

1700 mm (5’ 7”)

1770 mm (5’ 10”)

3420 mm

(11’ 3”)

M1J1-06-005

M111-06-007

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

M1J1-06-003

6-21

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 27600 kg (60850 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

27600

(60850)

28300

(62400)

NOTE: ** Removed the radiator front duct and cab handrail

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

3340

(7360)

5410 mm (17’ 9”)

3420 mm

(11’ 3”)

M1J1-06-004

M17P-06-015

M17V-06-024

Arm

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 109”)

4900

(16’ 1”)

A mm (ft•in)

4250

(13’ 11”)

4650

(15 ’31”)

5150

(16’ 11”)

6220

(20’ 5”)

Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.15

(1.5)

1.4

(1.8)

1.6

(2.1)

1.9

(2.5)

2.1

(2.7)

2.3

(3.0)

A mm (ft•in)

1800

(5’ 11”)

1800

(5’ 11”)

1960

(6’ 5”)

1960

(6’ 5”)

1960

(6’ 5”)

1950

(6’ 5”)

B mm (ft•in)

1250

(4’ 1”)

1100

(3’ 7”)

1100

(3’ 7”)

1150

(3’ 9”)

Width mm (ft•in)

740

(29”)

740

(29”)

740

(29”)

650

(26”)

B mm (ft•in)

1350

(4’ 5”)

1350

(4’ 5”)

1570

(5’ 2”)

1570

(5’ 2”)

1570

(5’ 2”)

1660

(5’ 5”)

Width mm (ft•in)

1210

(3’ 12”)

1410

(4’ 8”)

1360

(4’ 6”)

1540

(5’ 1”)

1630

(5’ 4”)

1660

(5’ 5”)

Weight kg (lb)

2400

(5300)

2330

(5100)

2640

(5820)

2550

(5620)

Weight kg (lb)

1070

(2360)

1170

(2580)

1480

(3260)

1590

(3500)

1650

(3640)

1800

(3970)

M111-06-004

6-22

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5'7")

515 mm

(20")

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

2470 mm (8’ 1”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

M17P-06-017

6-23

TRANSPORTING

ZAXIS470H

-3

(BACKHOE)

Packing Dimensions and Weights for Transportation - 1

Base Machine (Arm: H front)

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.

Weight: 47100 kg (103800 lb)

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

11910

(39’ 12)

B mm (ft•in)

3480

(11’ 5”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

47100

(103800)

47800

(105400)

NOTE: ** Removed the radiator front duct and cab handrail.

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150mm (6”)

515 mm

(20”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425mm (17”)

M1J1-06-006

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

M1J1-06-003

6-24

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine (Arm: H front)

Weight: 33200 kg (73200 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

33200

(73200)

33900

(74750)

NOTE: ** Removed the radiator front duct and cab handrail.

H Arm, Rock Bucket

Arm Length mm (ft•in)

3400

(11’2”)

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

6370

(20’ 11”)

B mm (ft•in)

1470

(4’ 10”)

Max.

Width mm (ft•in)

1460

(4’ 10”)

Weight kg (lb)

4630

(10200)

3450 mm

(11'4")

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

515 mm

(20”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425mm (17”)

9860 mm (32'4")

2960 mm (9’ 9”)

M1J1-06-008

M1J1-06-025

710 mm

(28”)

M1J1-06-015

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

M1J1-06-003

6-25

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 28200 kg (62200 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

28200

(62200)

28900

(63700)

NOTE: ** Removed the radiator front duct and cab handrail.

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

3560

(7850)

3450 mm

(11’ 4”)

5410 mm (17’ 9”)

H Arm

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

4650

(15 ’31”)

B mm (ft•in)

1100

(3’ 7”)

Width mm (ft•in)

740

(29”)

Weight kg (lb)

2560

(5650)

Rock Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

2030

(6’ 8”)

B mm (ft•in)

1480

(4’ 10”)

Width mm (ft•in)

1500

(4’ 11”)

Weight kg (lb)

2070

(4650)

M1J1-06-007

M17P-06-015

M17V-06-024

M1J1-06-026

6-26

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5’ 10”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

2470 mm (8’ 1”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

M17P-06-017

6-27

TRANSPORTING

ZAXIS450LC

-3

(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.

Weight: 46600 kg (102700 lb)

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 10”)

4900

(16’ 1”)

A mm (ft•in)

12000

(39’ 4”)

11910

(39’ 1”)

11910

(39’ 1”)

11910

(39’ 1”)

B mm (ft•in)

3600

(11’ 10”)

3480

(11’ 5”)

3500

(11’ 6”)

4500

(14’ 9”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

46600

(102700)

47400

(104500)

NOTE: ** Removed the radiator front duct and cab handrail.

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150mm (6”)

515 mm

(20”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

M1J1-06-001

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

M1J1-06-003

6-28

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine

Weight: 33300 kg (73400 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

33300

(73400)

34100

(75200)

NOTE: ** Removed the radiator front duct and cab handrail.

Arm, Bucket

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 109”)

4900

(16’ 1”)

Bucket Capacity

(PCSA heaped) m

(yd

)

2.3

(3.0)

2.1

(2.7)

1.9

(2.5)

1.4

(1.8)

A mm (ft•in)

6030

(19’ 9”)

6430

(21’ 1”)

6930

(22’ 9”)

7760

(25’ 6”)

B mm (ft•in)

1340

(4’ 5”)

1270

(4’ 2”)

1270

(4’ 2”)

1170

(3’ 10”)

Max.

Width mm (ft•in)

1660

(5’ 5”)

1630

(5’ 4”)

1540

(5’ 1”)

1410

(4’ 8”)

Weight kg (lb)

4200

(9260)

3980

(8770)

4230

(9330)

3720

(8200)

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

515 mm

(20”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

9860 mm (32’ 4”)

2960 mm (9’ 9”)

2340 mm (7’ 8”)

1700 mm (5’ 7”)

1770 mm (5’ 10”)

3420 mm

(11’ 3”)

M1J1-06-005

M111-06-007

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

M1J1-06-003

6-29

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 28500 kg (62800 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

28500

(62800)

29300

(64600)

NOTE: ** Removed the radiator front duct and cab handrail.

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

3340

(7360)

5630 mm (18’ 6”)

3420 mm

(11’ 3”)

M1J1-06-004

M17P-06-015

M17V-06-024

Arm

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 109”)

4900

(16’ 1”)

A mm (ft•in)

4250

(13’ 11”)

4650

(15 ’31”)

5150

(16’ 11”)

6220

(20’ 5”)

Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.15

(1.5)

1.4

(1.8)

1.6

(2.1)

1.9

(2.5)

2.1

(2.7)

2.3

(3.0)

A mm (ft•in)

1800

(5’ 11”)

1800

(5’ 11”)

1960

(6’ 5”)

1960

(6’ 5”)

1960

(6’ 5”)

1950

(6’ 5”)

B mm (ft•in)

1250

(4’ 1”)

1100

(3’ 7”)

1100

(3’ 7”)

1150

(3’ 9”)

Width mm (ft•in)

740

(29”)

740

(29”)

740

(29”)

650

(26”)

B mm (ft•in)

1350

(4’ 5”)

1350

(4’ 5”)

1570

(5’ 2”)

1570

(5’ 2”)

1570

(5’ 2”)

1660

(5’ 5”)

Width mm (ft•in)

1210

(3’ 12”)

1410

(4’ 8”)

1360

(4’ 6”)

1540

(5’ 1”)

1630

(5’ 4”)

1660

(5’ 5”)

Weight kg (lb)

2400

(5300)

2330

(5100)

2640

(5820)

2550

(5620)

Weight kg (lb)

1070

(2360)

1170

(2580)

1480

(3260)

1590

(3500)

1650

(3640)

1800

(3970)

M111-06-004

6-30

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5’ 10”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

2470 mm (8’ 1”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

M17P-06-017

6-31

TRANSPORTING

ZAXIS470LCH

-3

(BACKHOE)

Packing Dimensions and Weights for Transportation - 1

Base Machine (Arm: H front)

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.

Weight: 48100 kg (106000 lb)

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

11910

(39’ 12)

B mm (ft•in)

3480

(11’ 5”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

48100

(106000)

48900

(107800)

NOTE: ** Removed the radiator front duct and cab handrail.

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

515 mm

(20”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

M1J1-06-006

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

M1J1-06-003

6-32

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine (Arm: H front)

Weight: 34200 kg (75400 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

34200

(75400)

35000

(77200)

NOTE: ** Removed the radiator front duct and cab handrail.

H Arm, Rock Bucket

Arm Length mm (ft•in)

3400

(11’2”)

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

6370

(20’ 11”)

B mm (ft•in)

1470

(4’ 10”)

Max.

Width mm (ft•in)

1460

(4’ 10”)

Weight kg (lb)

4630

(10200)

3450 mm

(11’ 4”)

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

515 mm

(20”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

9860 mm (32’ 4”)

2960 mm (9’ 9”)

M1J1-06-008

M1J1-06-025

710 mm

(28”)

M1J1-06-015

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

M1J1-06-003

6-33

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 28200 kg (62200 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overal Width mm (ft•in)

(Except track side step)

3490/3070

(11’ 5”/10’ 1”)

3490/**3000

(11’ 5”/9’ 10”)

(Extended/Retracted)

3640/3140

(11’ 11”/10’ 4”)

(Extended/Retracted)

Weight kg (lb)

28200

(62200)

28900

(63700)

NOTE: ** Removed the radiator front duct and cab handrail.

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

3560

(7850)

3450 mm

(11’ 4”)

5630 mm (18’ 6”)

Arm (H front)

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

4650

(15 ’31”)

B mm (ft•in)

1100

(3’ 7”)

Width mm (ft•in)

740

(29”)

Weight kg (lb)

2560

(5650)

Rock Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

2030

(6’ 8”)

B mm (ft•in)

1480

(4’ 10”)

Width mm (ft•in)

1500

(4’ 11”)

Weight kg (lb)

2070

(4650)

M1J1-06-007

M17P-06-015

M17V-06-024

M1J1-06-026

6-34

Counterweight

Weight: 9150 kg (20200 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5’ 10”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

2470 mm (8’ 1”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

M17P-06-017

6-35

TRANSPORTING

ZAXIS500LCH

-3

(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.

Weight: 49500 kg (109100 lb)

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 10”)

4900

(16’ 1”)

A mm (ft•in)

11980

(39’ 4”)

11890

(39’ 0”)

11890

(39’ 0”)

11940

(39’ 2”)

B mm (ft•in)

3620

(11’ 11”)

3500

(11’ 6”)

3510

(11’ 6”)

4540

(14’ 11”)

515 mm

(20”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150mm (6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

3670/3170

(12’ 1”/10’ 5”)

Weight kg (lb)

49500

(109100)

50300

(110900)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Track Side Step

Weight: 18 kg (40 lb)

13 kg (29 lb) ×4

Height: 125mm (5”)

6-36

M1J1-06-009

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

540 mm (21”)

M1J1-06-003

215 mm (8”)

540 mm (21”)

90 mm (4”)

M162-06-014

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine

Weight: 35600 kg (78500 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

(Extended/Retracted)

3670/3170

(12’ 1”/10’ 5”)

(Extended/Retracted)

Arm, Bucket

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 109”)

4900

(16’ 1”)

Bucket Capacity

(PCSA heaped) m

(yd

)

2.3

(3.0)

2.1

(2.7)

1.9

(2.5)

1.4

(1.8)

Weight kg (lb)

35600

(78500)

36400

(80250)

A mm (ft•in)

6030

(19’ 9”)

6430

(21’ 1”)

6930

(22’ 9”)

7760

(25’ 6”)

B mm (ft•in)

1340

(4’ 5”)

1270

(4’ 2”)

1270

(4’ 2”)

1170

(3’ 10”)

Max.

Width mm (ft•in)

1660

(5’ 5”)

1630

(5’ 4”)

1540

(5’ 1”)

1410

(4’ 8”)

Weight kg (lb)

4200

(9260)

3980

(8770)

4230

(9330)

3720

(8200)

515 mm

(20”)

Counterweight

Weight: 9820 kg (21650 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Track Side Step

Weight: 18 kg (40 lb)

13 kg (29 lb) ×4

Height: 125mm (5”)

6-37

9830 mm (32’ 3”)

2960 mm (9’ 9”)

2340 mm (7’ 8”)

1700 mm (5’ 7”)

1770 mm (5’ 10”)

540 mm (21”)

3500 mm

(11’ 6”)

M1J1-06-011

M111-06-007

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

M1J1-06-003

215 mm (8”)

90 mm (4”)

M162-06-014

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 30800 kg (67900 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

(Extended/Retracted)

3670/3170

(12’ 1”/10’ 5”)

(Extended/Retracted)

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

30800

(67900)

31500

(69450)

Weight kg (lb)

3340

(7360)

5550 mm (18’ 3”)

Arm

Arm Length mm (ft•in)

2900

(9’ 6”)

3400

(11’ 2”)

3900

(12’ 109”)

4900

(16’ 1”)

A mm (ft•in)

4250

(13’ 11”)

4650

(15 ’31”)

5150

(16’ 11”)

6220

(20’ 5”)

Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.15

(1.5)

1.4

(1.8)

1.6

(2.1)

1.9

(2.5)

2.1

(2.7)

2.3

(3.0)

A mm (ft•in)

1800

(5’ 11”)

1800

(5’ 11”)

1960

(6’ 5”)

1960

(6’ 5”)

1960

(6’ 5”)

1950

(6’ 5”)

B mm (ft•in)

1250

(4’ 1”)

1100

(3’ 7”)

1100

(3’ 7”)

1150

(3’ 9”)

Width mm (ft•in)

740

(29”)

740

(29”)

740

(29”)

650

(26”)

B mm (ft•in)

1350

(4’ 5”)

1350

(4’ 5”)

1570

(5’ 2”)

1570

(5’ 2”)

1570

(5’ 2”)

1660

(5’ 5”)

Width mm (ft•in)

1210

(3’ 12”)

1410

(4’ 8”)

1360

(4’ 6”)

1540

(5’ 1”)

1630

(5’ 4”)

1660

(5’ 5”)

Weight kg (lb)

2400

(5300)

2330

(5100)

2640

(5820)

2550

(5620)

Weight kg (lb)

1070

(2360)

1170

(2580)

1480

(3260)

1590

(3500)

1650

(3640)

1800

(3970)

3500 mm

(11’ 7”)

M1J1-06-010

M111-06-004

M17P-06-015

M17V-06-024

6-38

Counterweight

Weight: 9820 kg (21650 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330 mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

Track Side Step

Weight: 18 kg (40 lb)

13 kg (29 lb) ×4

Height: 125 mm (5”)

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5’ 10”)

515 mm

(20”)

M1J1-06-002

1770 mm (5’ 10”)

2470 mm (8’ 1”)

750 mm

(30”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

540 mm (21”)

M17P-06-017

215 mm (8”)

540 mm (21”)

90 mm (4”)

M162-06-014

6-39

TRANSPORTING

ZAXIS520LCH

-3

(BACKHOE)

Packing Dimensions and Weights for Transportation - 1

Base Machine (Arm: H front)

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.

Weight: 51700 kg (114000 lb)

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

11890

(39’ 0”)

B mm (ft•in)

3500

(11’ 6”)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

(Extended/Retracted)

3670/3170

(12’ 1”/10’ 5”)

(Extended/Retracted)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Weight kg (lb)

51700

(114000)

51900

(114400)

515 mm

(20”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Track Side Step

Weight: 22 kg (40 lb)

13 kg (29 lb) ×4

Height: 125 mm (5”)

M1J1-06-012

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

580 mm (18”)

M1J1-06-003

223 mm (9”)

540 mm (21”)

90 mm (40”)

M162-06-014

6-40

TRANSPORTING

Packing Dimensions and Weights for Transportation - 2

Base Machine (Arm: H front)

Weight: 37000 kg (81600 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

(Extended/Retracted)

3670/3170

(12’ 1”/10’ 5”)

(Extended/Retracted)

Weight kg (lb)

37000

(81600)

37200

(82000)

H Arm, Rock Bucket

Arm Length mm (ft•in)

3400

(11’2”)

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

6370

(20’ 11”)

B mm (ft•in)

1470

(4’ 10”)

Max.

Width mm (ft•in)

1460

(4’ 10”)

Weight kg (lb)

4630

(10200)

Counterweight

Weight: 9820 kg (21650 lb)

Height: 1340 mm (4’ 5”)

3520 mm

(11’ 7”)

515 mm

(20”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm ( 6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm ( 6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Track Side Step

Weight: 22 kg (49 lb)

13 kg (29 lb) ×4

Height: 125 mm (5”)

9830 mm (32’ 3”)

2960 mm (9’ 9”)

M1J1-06-014

M1J1-06-025

710 mm

(28”)

M1J1-06-015

2340 mm (7’ 8”)

1700 mm (5’ 7”)

515 mm

(20”)

M1J1-06-002

750 mm

(30”)

1770 mm (5’ 10”)

580 mm (23”)

M1J1-06-003

223 mm (8”)

540 mm (21”)

90 mm (4”)

M162-06-014

6-41

TRANSPORTING

Packing Dimensions and Weights for Transportation - 3

Base Machine

Weight: 31900 kg (70300 lb)

Shoe Width mm (ft•in)

600

(2’ 0”)

750

(2’ 6”)

Overall Width mm (ft•in)

3520/3070

(11’ 7”/10’ 1”)

(Extended/Retracted)

3670/3170

(12’ 1”/10’ 5”)

(Extended/Retracted)

Boom

Boom Length mm (ft•in)

7.0

(22’ 12”)

A mm (ft•in)

7330

(24’ 1”)

B mm (ft•in)

1820

(5’ 12”)

Width mm (ft•in)

1110

(3’ 7”)

Weight kg (lb)

31900

(70300)

32100

(70800)

Weight kg (lb)

3560

(7850)

3520 mm

(11’ 7”)

5550 mm (18’ 3”)

Arm (H front)

Arm Length mm (ft•in)

3400

(11’ 2”)

A mm (ft•in)

4650

(15 ’31”)

B mm (ft•in)

1100

(3’ 7”)

Width mm (ft•in)

740

(29”)

Weight kg (lb)

2560

(5650)

Rock Bucket

Bucket Capacity

(PCSA heaped) m

(yd

)

1.9

(2.5)

A mm (ft•in)

2030

(6’ 8”)

B mm (ft•in)

1480

(4’ 10”)

Width mm (ft•in)

1500

(4’ 11”)

Weight kg (lb)

2070

(4650)

M1J1-06-013

M1J1-06-026

M17P-06-015

M17V-06-024

6-42

Counterweight

Weight: 9820 kg (21650 lb)

Height: 1340 mm (4’ 5”)

Side Step (Front)

Weight: 44 kg (97 lb)

Height: 150 mm (6”)

Side Step (Rear)

Weight: 30 kg (66 lb)

Height: 150 mm (6”)

Ladder

Weight: 23 kg (51 lb)

Height: 425 mm (17”)

Boom Cylinder

Weight: 420 kg (926 lb) ×2

Height: 330 mm (13”)

Hose

Weight: 9 kg (20 lb) ×4

Track Side Step

Weight: 22 kg (49 lb)

13 kg (29 lb) ×4

Height: 125 mm (5”)

TRANSPORTING

2960 mm (9’ 9”)

710 mm

(28”)

M1J1-06-015

515 mm

(20”)

2340 mm (7’ 8”)

1700 mm (5’ 10”)

515 mm

(20”)

M1J1-06-002

1770 mm (5’ 10”)

2470 mm (8’ 1”)

750 mm

(30”)

M1J1-06-003

490 mm

(19”)

M17P-06-016

1100 mm (3’ 7”)

580 mm (23”)

M17P-06-017

223 mm (8”)

540 mm (21”)

90 mm (4”)

M162-06-014

6-43

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. Operate the excavator with the side frames retracted only when loading or unloading the excavator onto and/or from a trailer. When the side frames are retracted overside, balance of the excavator will be reduced, potentially causing damage to the track frame, side frames, and bolts.

6-44

TRANSPORTING

RETRACTING THE SIDE FRAME

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. Remove eighteen mounting bolts (1) (9 used for each side) from the retracting side frames.

2. Retracting Side Frame (Track Gauge)

Turn the boom mode switch OFF so that the machine can be raised off the ground with front attachment.

3. Raise track (6) to be retracted using the front attachment, as illustrated.

Slowly rotate raised track (6) back and forth. The side frame will be retracted with its own weight and stop when it comes into contact with guide (2).

IMPORTANT: Maintain a 90 to 110° angle; never make an acute angle between the boom and the arm.

If side frame (4) does not retract completely, lower the undercarriage and turn the upperstructure 180°. Raise the opposite side track about 15° from the ground using the front attachment. Slowly push the arm out, to retract side frame

(4).

IMPORTANT: Do not raise track (6) excessively high or operate the arm-control lever abruptly. Damage to the track frame may result.

4. Slowly lower track (6) to the ground. Tighten six mounting bolts (5) (3 used for each side) to the specification.

Tightening Torque: 1750 N•m (179 kgf•m, 1290 lbf•ft)

5. Retract the opposite side, following procedures 1 to 4 above.

90 to 110°

15°

M111-06-008

M111-06-009

M111-06-010

6-45

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) .....................................4 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.

• Power Boost Wrench (including accessories), width across flats of the torque wrench: 50 mm

• Air Compressor (slide surface cleaning)

• Soft Protectors

WARNING:

• Group work is required. Before starting work, coordinate work procedures with co-workers.

• Damage to the lever block and/or wire rope may result along with severe personal injury. When extending the side fame using the front attachment, do not allow any personnel to enter the vicinity of the machine.

WARNING: Do not loosen side frame guide bolts (9).

IMPORTANT: When the machine is shipped from the factory, all side frame tightening bolts are not installed. Therefore, unbolted screw holes on the side frame are coated with rust-inhibitor so that they may be clogged with dust or soil. Before installing the tightening bolts, clean the thread surface thoroughly. If the bolts are difficult to tighten, tap the screw holes again.

Tap: M33, Pitch: 3 mm

IMPORTANT: Before working, completely clean the side frame slide surfaces using compressed air. If mud and/or gravel is stuck on the contact areas of track frame (2) and side frame (3), the work may be interrupted and loose mounting bolts (1) may result.

1. Remove side frame mounting bolts (1) (6 used, 3 bolts in two places) from the extending side frame.

2. Rotate the upper structure to the side of the extending side frame until the front attachment faces the side frame perpendicularly.

3. Set the arm and boom angle between 90° to 110°. Then, lower the bucket bottom to the ground.

90 to 110°

M111-06-011

M166-01-233

6-46

TRANSPORTING

4. Wind two wire ropes (4) around the front and rear sections (one wire rope on each section) of the side frame.

Connect lever block (5) to the ends of each wire rope.

Attach soft protectors (6) between the side frame (3) corners and wire ropes (4) to prevent damage to side frame

(3) and wire ropes (4).

5. Wind two wire ropes (8) around the arm near the bracket of bucket (7). Connect each rope ends to lever blocks (5).

Then, slowly extend the front attachment so that sag on wire ropes is removed. Attach soft protectors (6) between the bucket bracket corners and wire rope to prevent damage to wire ropes.

6. Retracting Side Frame (Track Gauge)

Turn the boom mode switch OFF so that the machine can be raised off the ground with front attachment.

7. While lowering the boom, raise the extending side frame approx. 50 mm (2 in) above the ground. If the side frame is raised too much, extending force increases.

8. Operate lever blocks (5) so that the rear (travel device side) and front (front idler side) of the side frame is equally extended until side frame guide (9) comes in contact with the track frame stopper.

WARNING: When the lever block becomes inoperable, it is because too much resistance exists against the extending force.

Avoid working by force. Otherwise, lever block and/or wire rope may be damaged and/or fly away possibly resulting in severe personal injury.

Stop the work and check if the front and rear of the side frame are equally extended or if the side frame is raised to the proper height.

Take corrective measures as necessary.

WARNING: After raising the side frame above the ground, never operate the arm to extend the side frame. If the arm is operated, the wire ropes are pulled with excessive tension force. Damage to the lever block or wire rope may result, possibly causing severe personal injury.

9. When side frame guide (9) comes in contact with the track frame stopper, install side frame tightening bolts (1)

(18 used) (9 used in two places) and tighten temporarily by hand. In case it is difficult to tighten with hand, bolt and screw hole centers may not be correctly aligned. Realign bolt and screw hole centers by operating the lever blocks.

6-47

M166-01-244

M162-06-062

M166-01-255

M111-06-013

TRANSPORTING

WARNING: Be sure to slowly operate the boom. If quickly operated, the lever block and/or wire rope may be damaged and/or fly away, possibly causing severe personal injury.

Stay away from the machine when operating the boom.

10. Slightly slacken wire rope tension by operating lever blocks (5) and raise the boom to slightly lower the track frame. Don’t slacken wire rope tension excessively. Also, take care not to lower the track frame excessively. If excessively slackened or lowered, side frame (3) will retract making re-tightening (by hand) of bolts difficult.

11. After slightly lowering track frame (2), re-tighten bolts (1) by hand.

12. Repeat steps 10 and 11 three to four times until the track frame is completely lowered to the ground.

13. Slacken the lever blocks. Remove the lever blocks and wire ropes.

14. Tighten bolts (1) with the power boost wrench and torque wrench to specification.

Tightening Torque: Refer to the under table.

IMPORTANT: Be sure to apply a film of lubricant to the bolt threads.

15. Extend the side frame on the opposite side in the same procedure.

M166-01-256

M111-06-013

Model

ZAXIS450

-3

450LC

-3

470H

-3

470LCH

-3

ZAXIS500LC

-3

520LCH

-3

Bolt Size

M33-Pitch 3

Width across Flats (mm)

Torque

N•m (kgf•m, lbf•ft)

1750 (179, 1290)

50 2200 (220, 1590)

Note

6-48

MAINTENANCE

CORRECT MAINTENANCE AND INSPECTION

PROCEDURES

Learn how to service your machine correctly. Follow the correct maintenance and inspection procedures shown in this manual.

Inspect machine daily before starting.

• Check controls and instruments.

• Check coolant, fuel and oil levels.

• Check for leaks, kinked, frayed or damaged hoses and lines.

• Walk around machine checking general appearance, noise, heat, etc.

• Check for loose or missing parts.

If there is any problem with your machine, repair it before operating or contact your authorized dealer.

IMPORTANT: • Use only recommended fuel and lubri-

cants.

• Be sure to use only genuine Hitachi parts.

Failure to do so may result in serious injury or death and/or machine breakdown.

• Use only genuine HITACHI parts.

• Failure to use recommended fuel, lubri-

cants, and genuine Hitachi parts will result in loss of Hitachi product warranty.

• Never adjust engine governor or hydraulic

system relief valve.

• Protect electrical parts from water and

steam.

• Never disassemble electrical components

such as main controller, sensors, etc.

SA-005

7-1

MAINTENANCE

CHECK THE HOUR METER REGULARLY

• Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in more adverse conditions, you should service it at

SHORTER INTERVALS.

• Lubricate, make service checks and adjustments at intervals shown on periodic maintenance guide table. (See page 7-6)

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.

7-2

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.

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. Run the engine at slow idle speed without load for five minutes.

5. Turn the key switch OFF. Remove the key from the key switch. (If maintenance must be performed with engine running, do not leave machine unattended.)

6. Pull the pilot control shut-off lever (1) to the LOCK position.

7. Before performing any work on the machine, attach a “Do

Not Operate” tag on the right control lever.

M104-07-021

M1U1-07-059

SS2045102

7-3

MAINTENANCE

HOOD AND ACCESS COVERS

• 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 covers may close accidentally, possibly resulting in personal injury.

• When opening or closing the hood and access covers, take extra care not to catch fingers between the base machine and the hood or access covers.

Secure Engine Hood in Position

When opening the engine access cover, unlatch the cover in 2 places, and hold the cover handle. Then, raise the cover until stay (1) lock completely engages with lock groove (2) inside the cover.

Catch

Cover Handle

Engine Cover

Catch

M1J1-07-031

M1J1-07-038

Air Cleaner Cover

Secure Access Covers in Position

Open each access cover and air cleaner access cover. Insert the end of rod (3) into locking hole (4) to lock the access cover in position.

Right Side Cover

M1J1-07-033

Left Side Cover

M1J1-07-011

7-4

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. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval.

Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.

Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary.

Consult your authorized dealer for correct replacement.

Hydraulic

System

Engine

Front-End

Attachment

Other

Periodic Replacement Parts

Base Machine

Fuel hose (Fuel tank to filter)

Fuel hose (Fuel tank to injection pump)

Heater hose (Heater to engine)

Pump suction hose

Pump delivery hose

Swing hose

Travel hose

Boom cylinder line hose

Arm cylinder line hose

Bucket cylinder line hose

Pilot hose

Seat belt

NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.

Replacement

Intervals

Every 2 years or Every 6000 hours

Every 3 years

7-5

MAINTENANCE

MAINTENANCE GUIDE

A. GREASING (See Page 7-9)

Parts Quantity

1 Front Joint

Pins

2. Swing Bearing

Boom Pivot

Boom Cylinder

Bottom End

Bucket and Link Pins

Others

3. Swing Internal Gear

Backhoe

NOTE: ★ Grease every 10 hours for first 100 hours.

★★

Maintenance required when operating in water or mud.

★

★★

★

Interval (hours)

100 250 500 1000 2000

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 OIL (See Page 7-20)

Parts

1. Engine oil

2. Engine oil

Oil Level Check

Change

3. Engine oil Filter Replacement

Quantity

—

57 L (15.1 US gal)

10 50

Interval (hours)

100 250 500 1000 2000

C. TRANSMISSION OIL (See Page 7-24)

Parts Quantity

1. Swing Reduction Gear

2. Travel

Reduction

Gear

ZAXIS450

-3

470H

-3

, 450LC

-3

470LCH

-3

ZAXIS500LC

-3

520LCH

-3

Oil Level Check

Change

Oil Level Check

Change

Oil Level Check

Change

6.5 L×2 (1.7 US gal×2)

11 L×2 (2.9 US gal×2)

14 L×2 (3.7 US gal×2)

Interval (hours)

50 100 250 500 1000 2000

7-6

MAINTENANCE

D. HYDRAULIC SYSTEM (See Page 7-28)

Parts Quantity

Interval (hours)

10 50 100 250 500 1000 1500 2500 4000

1. Check Hydraulic Oil Level

2. Drain Hydraulic Oil Tank Sump

3. Change Hydraulic Oil

4. Suction Filter Cleaning

5. Replace Hydraulic Oil Tank Filter

6. Replace Pump Drain Filter

7. Replace Pilot Oil Filter

8. Replace Air Breather Filter

9. Check Hoses and Lines for leaks for cracks, bend, etc.

560 L (148.0US gal)

—

NOTE: ✸ Hydraulic oil changing interval differs according to the kind of hydraulic oil used.

See recommended oil chart.

✸

When changing hydraulic oil

✸ ✸

E. FUEL SYSTEM (See Page 7-45)

10 50

Tank capacity 725 liter (192 US gal)

Interval (hours)

100 250 500 1000 2000

Parts

1. Drain Fuel Tank Sump

2. Check Water Separator

3. Replace Fuel Main Filter

4. Replace Fuel Pre-Filter

5. Clean Feed Pump Strainer

6. Check Fuel

Hoses for leaks for cracks, bend, etc.

Quantity

—

F. AIR CLEANER (See Page 7-54)

Parts

1. Air Cleaner Outer Element

2. Air Cleaner Inner Element

Cleaning

Replacement

Quantity

10 50

Interval (hours)

100 250 500 1000 2000

(Or when indicator lit)

After cleaning 6 times or 1 year

When outer element is replaced

G. COOLING SYSTEM (See Page 7-56)

Parts Quantity

10 50

Interval (hours)

100 250 500 1000 2000

1. Check Coolant Level

2. Change Coolant

3. Clean Radiator, Oil Cooler,

Inter Cooler, Fuel Cooler Core

4. Clean Oil Cooler Front Screen

Outside

Inside

55 L (14.5 US gal)

Twice a year ✸

Once a year

★

NOTE: ★ Shorten maintenance interval when the machine is operated in dusty areas.

✸

When genuine Hitachi coolant is used, replace every two years or 4000 operating hours, whichever comes first.

7-7

MAINTENANCE

H. AIR CONDITIONER (See Page 7-61)

Parts

1. Circulating Air Filter

Cleaning

Replacement

Fresh Air Filter

Cleaning

Replacement

2. Check Refrigerant (Gas) Quantity

3. Check Compressor Belt Tension

4. Clean Condenser Core

5. Check Looseness at each of Fastened

Areas

6. Check In-Season and Off-Season

Quantity

—

10 50

Interval (hours)

100 250 500 1000 2000

When excessively restricted

Twice a year

I. ELECTRICAL SYSTEM (See Page 7-67)

1. Battery

2. Replace Fuse

Parts

Level Check

Specific Gravity

Quantity

—

10 50

Interval (hours)

100 250 500 1000 2000

Every month

As required

J. MISCELLANEOUS (See Page 7-74)

Parts Quantity

1. Check Bucket Teeth for Wear and Looseness

2. Change Bucket

3. Adjust Bucket Linkage

4. Remove Travel Levers

5. Check and Replace Seat Belt

6. Check Windshield Washer Fluid Level

7. Check Track Sag

8. Clean Cab Floor

9. Check Tightening Torque of Bolts and Nuts

10. Check O-rings in Bucket Joints

11. Retighten Cylinder Head Bold

12. Inspect and Adjust Valve Clearance

13. Check fuel Injection Timing

14. Measure Engine Compression Pressure

15. Check Starter and Alternator

16. Check Water Pump

NOTE: ★★★ Maintenance required only during first time check.

✹

Contract your authorized dealer for maintenance.

—

Interval (hours)

10 50 100 250 500 1000 2000 4000

★★★

As required

Every 3 years (Replace)

As required

✹

As required

✹

7-8

MAINTENANCE

A. GREASING

Parts Quantity

1 Front Joint

Pins

2. Swing Bearing

Boom Pivot

Boom Cylinder

Bottom End

Bucket and Link Pins

Others

3. Swing Internal Gear

Backhoe

NOTE: ★ Grease every 10 hours for first 100 hours.

★★

Maintenance required when operating in water or mud.

★

★★

★

1

Interval (hours)

100 250 500 1000 2000

1

3

1

2

Where to be

applied

Manufacturer

Nippon Koyu

British Petroleum

Caltex Oil

Esso

Idemitsu Kosan

Mobil Oil

Nippon Oil

Shell Oil

Brand Names of Recommended Grease

Bucket, Arm and Boom, Swing Gear,

Swing Bearing, etc.

–20 to 45 °C (–4 to 113 °F)

SEP 2

BP Energrease

Multifax

Beacon

✸

LS-EP2

EP2

Daphne Coronex Grease EP2

Mobilux EP2

Epinoc Grease

Shell Alvania

AP2

EP2 ✸2

NOTE: The machine shipped from the factory is filled with lubricants marked with .

✸1 Front Joint Pin and Swing Bearing

✸2 Swing Gear

7-9

M1J1-01-001

MAINTENANCE

AUTOMATIC LUBRICATION --- IF EQUIPPED

The automatic lubrication device uses a controller-built-in, 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 indicators (4), (5) display.

The electric pump (1) is set to operate for duration of approximately 2 minutes at 3 operating hour intervals.

The electric pump (1) is located in the right front cover.

Electric pump (1) and grease tank (6) are all-in-one designs.

The following points are lubricated by the automatic lubrication device.

As for the bucket and link pins, use a grease gun to lubricate them. (Refer to the heading “Greasing” in the “MAINTE-

NANCE” section.)

Check Grease Quantity/Add Grease

Check Grease Quantity:

1. Park the machine on a firm, level surface.

2. Lower the bucket to the ground.

3. Check remaining grease quantity in grease tank (6) located in the tool box.

Add grease as necessary referring to the procedures below.

IMPORTANT: Check grease tank (6) and add grease as needed so that the tank does not become empty. If the electric pump is operated with the grease tank empty, air will get into lubrication lines, resulting in insufficient lubrication.

Adding Grease Using Specially Designed Refilling Pump:

1. Insert the grease cartridge 0.4 liter into refilling pump (7).

2. Remove the filler cap (8) from top of grease tank (6).

3. Apply the tip of refilling pump (7) to the filler (9) opening of grease tank (6), and secure the joint using cap nut (10).

4. Slowly push the handle (11) straight into refilling pump (7) to the stop.

5. Remove refilling pump (7). Securely tighten cap (8) onto the filler opening.

M1J1-03-001

M1J1-01-002

M1JB-07-050

M1JB-07-051

M1JB-07-052

7-10

MAINTENANCE

Adding Grease Via Grease Fittings Using Grease Gun:

Add grease into the grease tank (6) via the grease fitting located on the top of the tank using a electric grease gun.

Note that grease may not be able to added via the grease fitting in cold weather as grease becomes hard. Be sure to fill the tank full before this happens so that adding grease is not required while the weather is cold. If adding grease is required in cold weather, warm the grease cartridge, then add using the specially designed refilling pump described above. (The capacity of the tank is approximately 2 liters which could cover approximately 2000 to 2400 operating hours.)

IMPORTANT: • Check grease tank (6) and add grease as needed so that the tank does not become empty. If the electric pump (1) is operated with the grease tank empty, air will get into lubrication lines, resulting in insufficient lubrication.

• Do not remove grease tank upper cover

(13) when greasing. Sand and garbage may enter into the grease tank (6).

Take special care to keep clean free from dirt when refilling.

• Be careful not to allow dust to enter grease tank (6). The electric pump (1) may be damaged if dust becomes mixed into the auto lubrication system.

NOTE: The electric pump (1) is equipped with a safety valve.

If the pump delivery pressure exceeds 34 MPa (350 kgf/cm

, 4980 psi), grease will be discharged from the safety valve. If this happens, contact your authorized dealer for inspection.

Also, contact your authorized dealer for any failure of equipment or lines, or for any inquiries.

M1JB-07-050

M1JB-07-052

7-11

1

Front Joint Pins (BACKHOE)

Bucket and Link Pins --- every 10 hours

MAINTENANCE

Others --- every 50 hours

(every 10 hours for first 100 hours)

This machine can be lubricated through grease fittings without using the auto lubrication device by following the procedure below.

NOTE: When greasing the backhoe front attachment, fully extend the arm cylinder, lower the boom until the bucket comes in contact with the ground, and adjust the bucket cylinder stroke so that the bucket bottom is approximately upright to the ground as illustrated to the right. This position allows easy access to all greasing points.

• Boom Pivot

(When the auto lubrication device is not used)

• Boom Cylinder Bottom End

(When the auto lubrication device is not used)

• Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket

Cylinder Bottom Pin.

(When the auto lubrication device is not used)

Vertical

M1J1-07-057

M1J1-07-050

M116-07-002

M111-07-008

7-12

MAINTENANCE

• Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin.

(Centralized greasing system)

(When the auto lubrication device is not used)

• Bucket and Link Pins every 10 hours

M1J1-07-050

M1J1-07-058

7-13

MAINTENANCE

2

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 bearing, clear the area of all persons.

Each time you leave the cab

• Lower the bucket to the ground.

• Stop the engine.

• Pull the pilot control shut-off lever to the LOCK position.

• Use handrails.

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. Run the engine at slow idle speed without load for five minutes.

5. Turn the key switch OFF. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

7. With the upperstructure stationary, apply grease via the three grease fittings.

8. Start the engine. Raise the bucket several inches off the ground and rotate the upperstructure 40° (1/9 turn).

9. Lower the bucket to the ground.

10. Repeat the procedure three times, beginning with step 7.

11. Apply grease to the swing bearing until grease can be seen escaping from the swing bearing seals.

12. Total amount of grease to be applied is approximately 3 to 4 strokes by grease lubricator.

13. Take care not to supply excessive grease.

M111-07-010

7-14

MAINTENANCE

ELECTRIC GREASE GUN --- IF EQUIPPED

WARNING: The electric grease gun is not a waterproof type. Don’t 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. No specified daily maintenance is required. Take care not to collide the gun, the motor section especially, with an other object, or not to leave the gun dirty. Failure to do so may result in unexpected injury such as an electric shock. Be sure to keep the electric grease gun clean by wiping off after use. If left contaminated, the grease gum may slip out of your hand, possibly causing a foot injury.

Part Name

1- Switch

2- Motor Unit

3- Nozzle (CPN-2)

4- Cap

5- Grease Cartridge

6- Checking Port

7- Oil Cylinder

8- Chain

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 (7) from motor unit (2).

2. Pull chain (8) all the way out of oil cylinder (7) and hang the chain on the notch on the bottom groove of oil cylinder (7).

3. Remove cap (4) from grease cartridge (5). Install grease cartridge (5) into the screw hole on motor unit (2).

IMPORTANT: If grease cartridge (5) is diagonally or forcibly tightened, damage to the screw threads may result so that grease cartridge (5) may not be properly installed to motor unit (2).

4. Install oil cylinder (7) in the original position on motor unit (2). Unhinge chain (8) from the notch.

M16J-07-044

M16J-07-042

M16J-07-043

7-15

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).

NOTE: When using the grease gun first time, it takes time for air to be bled before grease is delivered.

2. After cleaning the grease fitting to be greased and the tip of grease gun nozzle (3), install the tip of nozzle (3) onto the grease fitting.

3. Pull switch (1) to supply grease. When grease is normally supplied, old grease will be pushed out of the clearances around the grease fitting.

4. After greasing is complete, bleed the pressure remaining in the grease gun by tilting the nozzle before disconnecting nozzle (3) from the grease fitting. A small amount of grease will spout at this moment.

NOTE: If the motor speed becomes extremely slow or stops, immediately release the switch.

Since the grease gun operates at high speed, a small amount of grease may leak from the plunger. However, this is not a failure.

M16J-07-044

Grease Fitting

M16J-07-045

Grease Fitting

M16J-07-046

7-16

MAINTENANCE

LUBRICATOR --- IF EQUIPPED

1. Lubricator Operation

(1) Turn power switch (8) ON to activate the pump (1).

Grease is sucked up and supplied to high-pressure grease gun (3).

IMPORTANT: When the pump begins to suck grease, any air inside pump (1) will be mixed in, making grease turn whitish. Open check valve cock

(2) to bleed this air-mixed grease. Securely close check valve cock (2) when all air-mixed grease is bled out.

(2) Get high-pressure grease gun (3) and pay out the hose from hose reel (4) to the length required.

(3) Press hydro-chuck (5) protruding from high-pressure grease gun (3) into a grease nipple and pull the lever to discharge grease.

(4) Release the lever when greasing is complete; grease discharge will stop.

IMPORTANT: When detaching hydro-chuck (5) from grease nipple (7), grease nipple (7) tip may break unless a special care, is taken, as follows:

• Tilt nozzle (6) a little so as to release the connecting pressure applied to hydro-chuck (5).

• Slowly detach hydro-chuck (5) from nipple (7).

(5) When all greasing work is complete, turn power switch

(8) OFF, then pull grease gun (3) lever to release remaining pressure from grease gun (3), pump (1), and the hose so as to ensure long life of the components. A little grease will be discharged at this time.

NOTE: The hose has a limited service life. Periodically inspect the hose for cracks, grease leakage, or any other damage. If any damage is found, replace the hose.

M111-07-011

M111-07-012

M111-07-013

7-17

MAINTENANCE

2. Grease Container Replacement

When the grease container becomes empty, follow the procedure below to replace it.

IMPORTANT: When replacing the grease container, be sure that no sand or debris sticks to suction tube

(5) or to follower plate (3). If foreign matter, such as sand, gets into grease, damage to the pump and to parts being lubricated will result. If follower plate (3) is not correctly positioned inside the container, the pump may not suck grease, even with grease remaining in the container. Reposition the plate correctly if this happens.

(1) Loosen wing nuts (2) located on pail cover (7).

Remove the pump assembly (pump (1), pail cover (7), and suction tube (5)) and follower plate (3) from the empty grease container (4).

(2) Remove the cover from the new grease container.

(3) Apply grease to the back of follower plate (3) to fill concaved sections; this will prevent air from mixing into the grease contents.

(4) Place follower plate (3) flat on the grease contents in the container. Using both hands, press follower plate (3) down while moving both hands back and forth along the periphery of the container inside, as illustrated, until grease comes out of seal packing (6) hole.

IMPORTANT: Be careful not to damage seal packing (6) by the end of suction tube (5) when inserting it.

(5) Slowly insert suction tube (5) (the pump assembly) into the grease contents via the seal packing hole.

(6) Be sure that pail cover (7) correctly settles on the container. Equally tighten each wing nut (2) to pail cover

(7) to securely attach the pump assembly onto the container.

Grease Container

M1J1-07-059

M111-07-014

M111-07-087

7-18

MAINTENANCE

3

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

• Lower the bucket to the ground.

• Stop the engine.

• Pull the pilot control shut-off lever to the LOCK position.

• Use handrails.

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. Run the engine at slow idle speed without load for five minutes.

5. Turn the key switch OFF. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

7. Remove the cover (1) on the upper structure .

8. Grease must be to the top of all internal gear teeth of the swing bearing and be free of contamination by dirt and water.

Add approximately 0.5 kg (1.1 lb) of grease, if required. If the grease is contaminated, remove grease and replace with clean grease.

9. Install the cover (1).

10. If grease shows any sign of water or mud, replace all the grease on the internal gear.

Remove cover (2) from the bottom of the swing gear housing, located near the center joint.

Grease capacity: 16 to 18 liter (4.2 to 4.8 US gal)

M1J1-07-024

M116-07-042

7-19

MAINTENANCE

B. ENGINE OIL

Parts

1. Engine oil

2. Engine oil

Oil Level Check

Change

3. Engine oil Filter Replacement

Quantity

—

57 L (15.1 US gal)

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 noted that all engine failures caused by using engine oil other than specified are excluded from Hitachi Warranty Policy. Consult your nearest

Hitachi dealer for the unclear points.

Depending upon the expected air temperature range between oil changes, use the oil viscosity shown on the temperature chart below.

10 50

Interval (hours)

100 250 500 1000 2000

Kind of Oil

Application

Brand Names of Recommended Engine Oil

Engine Oil

Engine Crank Case

Air Temp.

-20 to 30 °C

(-4 to 86 °F)

-15 to 45 °C

(5 to 113 °F)

Standard

Manufacturer

HITACHI

Supper wide

DH-1 10W30

Supper wide

DH-1 15W40

JASO

DH-1

7-20

MAINTENANCE

1

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).

2. Remove dipstick (1) again. Read level. Oil level must be between the circle marks.

3. If necessary, add oil via oil filler cap (2).

Be sure to use only recommended oil (see Recommended

Engine Oil Chart).

NOTE: Checking the oil level immediately after shut down will result in inaccurate readings.

Be sure to allow the oil to settle for at least 10 minutes before checking.

M1J1-07-022

Upper Level

Lower Level

M178-07-011

7-21

MAINTENANCE

2

Change Engine Oil --- every 500 hours

IMPORTANT: Depending on the fuel quality to be used, the change intervals of engine oil and engine oil filter vary. Consult your nearest Hitachi dealer for the details.

3

Replace Engine Oil Filter

--- every 500 hours

IMPORTANT: Depending on the fuel quality to be used, the change intervals of engine oil and engine oil filter vary. Consult your nearest Hitachi dealer for the details.

1. Run the engine to warm oil.

DO NOT run the engine until oil is hot.

2. Park the machine on a level surface.

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Run the engine at slow idle speed without load for five minutes.

6. Turn the key switch OFF. Remove the key from the key switch.

7. Pull the pilot control shut-off lever to the LOCK position.

3, 4

WARNING: Engine oil may be hot. Take extra care to avoid burns.

8. Remove oil filler cap (2).

IMPORTANT: Install drainer (5) to the drain valve slowly.

Oil may exhaust in large quantities when suddenly tightened.

9. Remove cap (4) from oil pan drain valve (3). Install drainer

(5) to the drain valve.

10. Screw drainer (5) into drain valve. Drain valve (3) will be opened to drain oil.

11. Remove oil filler cap (2). Then, allow oil to drain through a clean cloth into a 60-liter (16 US gal) container.

12. After all oil has been drained, inspect the cloth for any debris such as small pieces of metal.

13. Remove drainer (5). Install cap (4) to drain valve (3).

Oil

Screw

Oil Pan

Clean Cloth

Container

Oil

M1J1-07-022

M1U1-07-045

M1U1-07-046

Oil Pan

M1U1-07-002

M104-07-010

7-22

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. Apply a thin film of clean oil to the gasket of the new filter.

18. Install new filter. Turn the filter cartridge clockwise by hand until the gasket touches the contact area. Be sure not to damage the gasket when installing the filter.

19. Tighten engine oil filter (6) 3/4 to 1 turn more using the filter wrench.

Be careful not to overtighten.

20. Remove the oil filler cap. Fill the engine with recommended oil. Check that oil level is between the circle marks on the dipstick after 15 minutes.

21. Install the oil filler cap.

22. Start the engine. Run the engine at slow idle for 5 minutes.

23. Check that the engine oil pressure indicator on the monitor panel goes out immediately. If not, stop the engine immediately and find the cause.

24. Stop the engine. Remove the key from the key switch.

25. Check for any leakage at the drain plug.

26. Check oil level on the dipstick.

NOTE: Do not re-use the cartridge element.

M1J1-07-008

7-23

MAINTENANCE

C. TRANSMISSION OIL

Parts Quantity

1. Swing Reduction Gear

2. Travel

Reduction

Gear

ZAXIS450

-3

470H

-3

, 450LC

-3

470LCH

-3

ZAXIS500LC

-3

520LCH

-3

Oil Level Check

Change

Oil Level Check

Change

Oil Level Check

Change

6.5 L×2 (1.7 US gal×2)

11 L×2 (2.9 US gal×2)

14 L×2 (3.7 US gal×2)

Interval (hours)

50 100 250 500 1000 2000

1

Application

Kind of Oil

Air Temp.

Manufacturer

British Petroleum

Caltex Oil

Esso

Mobil Oil

Nippon Oil

Shell Oil

Swing and Travel Reduction Gear

Gear oil

BP Gear oil

–20 to 45 °C (–4 to 113 °F)

Universal Thuban

Esso Gear Oil

Idemitsu Kosan Apollo Gear

Mobilube

Gear Lube SP90

Shell Spirax

2

Brand Names of Recommended Oil

SAE90EP

SAE 90

80W-90, 85W-90

HE90

GX90

(Swing and travel reduction device)

EP90

✸

Remarks API GL 4 Class

NOTE: The machine shipped from the factory is filled with oil marked

✸

Engine oil (15W-40) for pump transmission

✸

Gear oil for swing and travel reduction device

Engine/gear oil can be used for pump transmission.

M1J1-01-001

Pump Transmission

Engine Oil or Gear Oil (shown in left column)

–20 to 40 °C

(–4 to 104 °F)

–10 to 35 °C

(14 to 95 °F)

–25 to 40 °C

(–13 to 104 °F)

BP Vanellus C3

RPM DELO 300 Oil

30 40

Apolloil super wide

15W-40

Essolube D-3

30 40

Apolloil diesel motive

S-330 S-340

1330

Mobil Delvac

1340

Hidiesel S3

15W-40 ✸1

–20 to 35 °C

(–4 to 95 °F)

10W-30

Rymla D

API CD Class

7-24

MAINTENANCE

1

Swing Reduction Gear

Check Oil Level --- every 250 hours

1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

4. Run the engine at slow idle speed without load for three minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Gear oil may be hot. Wait for gear oil to cool before starting work.

7. Remove dipstick (1). Oil must be between marks.

8. If necessary, remove oil supply cap (2) and add oil. (See gear oil chart)

9. Recheck oil level.

Speciﬁed Range

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. Run the engine at slow idle speed without load for three minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Gear oil may be hot. Wait for gear oil to cool before starting work.

7. Remove drain plugs (4) mounted on the end of drain pipe and open drain cocks (3) to drain oil.

8. Reinstall drain plugs (4) and close drain cocks (3).

9. Remove oil supply caps (2) and add oil until it is between marks on dipsticks (1).

7-25

M104-07-021

M1J1-07-001

M16J-07-048

M1J1-07-053

M1J1-07-018

MAINTENANCE

2

Travel Reduction Gear

Check Oil Level --- every 250 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. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Run the engine at slow idle speed without load for three minutes.

6. Stop the engine. Remove the key from the key switch.

7. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Keep body and face away from the air release plug. Gear oil is hot. Wait for gear oil to cool and then gradually loosen the air release plug to release pressure.

8. After gear oil has cooled, slowly loosen air release plug (1) to release pressure.

9. Remove air release plug (1) and oil level check plug (2).

Oil must be up to the bottom of hole.

10. If necessary, add oil until oil flows out of the oil level check plug hole. (See gear oil chart)

11. Wrap the plug threads with sealing-type tape. Install plugs (1) and (2).

Tighten plugs (1) and (2) to 70 N•m (7 kgf•m, 51 lbf•ft).

12. Check the gear oil level in the other travel reduction gear.

Air Release Plug 1

(oil Supply Plug)

Horizontal Oil Level

Oil Level Check

Plug 2

Drain Plug 3

M107-07-096

M166-07-012

7-26

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. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Run the engine at slow idle speed without load for three minutes.

6. Stop the engine. Remove the key from the key switch.

7. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Keep body and face away from the air release plug. Gear oil is hot. Wait for gear oil to cool and then gradually loosen the air release plug to release pressure.

8. After gear oil has cooled, slowly loosen air release plug (1) to release pressure.

9. Remove drain plug (3) to drain oil.

10. Wrap the threads of the drain plug with sealing-type tape. Install the plug.

Tighten the plug to 70 N•m (7.1 kgf•m, 51 lbf•ft).

11. Remove oil level check plug (2).

12. Add oil until oil flows out of the oil level check plug hole.

(See gear oil chart)

13. Wrap the threads of oil level check plug (2) and air release plug (1) with sealing-type tape. Reinstall the plugs.

Tighten the plugs to 70 N•m (7.1 kgf•m, 51 lbf•ft).

14. Repeat steps 8 to 13 for the other travel reduction gear.

M166-07-012

7-27

MAINTENANCE

D. HYDRAULIC SYSTEM

Parts Quantity

Interval (hours)

10 50 100 250 500 1000 1500 2500 4000

1. Check Hydraulic Oil Level

2. Drain Hydraulic Oil Tank Sump

3. Change Hydraulic Oil

4. Suction Filter Cleaning

5. Replace Hydraulic Oil Tank Filter

6. Replace Pump Drain Filter

7. Replace Pilot Oil Filter

8. Replace Air Breather Filter

9. Check Hoses and Lines for leaks for cracks, bend, etc.

560 L (148.0US gal)

—

NOTE: ✸ Hydraulic oil changing intervals differ according to kind of hydraulic oil used.

See recommended oil chart.

✸

When changing hydraulic oil

✸ ✸

1 2 3

4 5

8

6

7

M1J1-01-001

Brand Names of Recommended HydraulicOil

Kind of Lubricant

Where to be applied

Change Interval

Environmental

Temp.

Manufacturer

Hitachi

Idemitsu Kosan

British Petroleum

Caltex Oil

Texaco INC.

Chevron U.S.A INC.

Esso

Mobil Oil

Shell Oil

Remarks

4000 hours

–20 to 40°C

(–4 to 104°F)

–10 to 40°C

(14 to 104°F)

Super EX 46HN

Hydraulic Oil

Hydraulic System

2500 hours

–20 to 40°C

(–4 to 104°F)

–10 to 40°C

(14 to 104°F)

Super Hydro 46 WRHU

1500 hours

–20 to 40°C

(–4 to 104°F)

Bartran HV46

–10 to 40°C

(14 to 104°F)

Rando Oil HD46

Chevron AW46

NUTO H46

DTE 25

Tellus Oil 46 Tellus Oil S46

Anti-wear type hydraulic oil

NOTE: Use proper hydraulic oil in accordance with the atmospheric temperature.

The machine shipped from the factory is filled with oil marked .

When the atmospheric temperature is between -40°C and +20°C: Use the proper hydraulic oil having high and low temperature characteristics by referring to the values shown below.

Low Temperature Viscosity: Less than 4000cSt at -40°C

High Temperature Viscosity: More than 6.5cSt at +80°C

The above values are approximately equivalent to ISO viscosity grade #22. However, low temperature viscosity will differ depending on each product. Contact each hydraulic oil manufacture directly.

When the atmospheric temperature is below -40°C: Contact your authorized dealer.

7-28

MAINTENANCE

INSPECTION AND MAINTENANCE OF

HYDRAULIC EQUIPMENT

IMPORTANT: Do not adjust the engine governor and/or hydraulic components.

WARNING: During operation, the parts of the hydraulic system become very hot.

Allow the machine to cool down before beginning inspection or maintenance.

1. Be sure that the machine is parked on a level, firm surface before servicing hydraulic equipment.

2. Lower the bucket to the ground and stop the engine.

3. Begin servicing hydraulic components only after components, hydraulic oil and lubricants are completely cooled, and after releasing residual pressure.

3.1 Bleed air from the hydraulic oil tank to release internal pressure.

3.2 Allow the machine to cool down.

Note that servicing heated and pressurized hydraulic components may cause hot parts and/or oil to fly off or escape suddenly, possibly resulting in personal injury.

3.3 Keep body parts and face away from plugs or screws when removing them.

Hydraulic components may be pressurized even when cooled.

3.4 Never attempt to service or inspect the travel and swing motor circuits on slopes. They are highly pressurized due to self-weight.

3.5 Even after bleeding the air from the hydraulic oil tank, pressure remains in the various circuits of the hydraulic system. Be sure to operate each control lever a few times to release residual pressure from the system.

4. When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them. Keep these precautions in mind:

4.1 Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them.

4.2 Only use O-rings that are free of damage or defects. Be careful not to damage them during reassembly.

4.3 Do not allow high pressure hoses to twist when connecting them. The life of twisted hoses will be shortened considerably.

4.4 Carefully tighten low pressure hose clamps.

Do not over tighten them.

7-29

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.

6. Do not use hydraulic oils other than those listed in the table “Brand names of recommended hydraulic oil”.

7. Never run the engine without oil in the hydraulic oil tank.

7-30

MAINTENANCE

1

Check Hydraulic Oil Level --- daily

IMPORTANT: Never run the engine without oil in hydraulic oil tank.

1. Park the machine on a level surface.

2. (Backhoe)

Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended.

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Run the engine at slow idle speed without load for five minutes.

6. Turn the key switch OFF. Remove the key from the key switch.

7. Pull the pilot control shut-off lever to the LOCK position.

8. Open the access door in front of the main pump. Check oil level with level gauge (1) on hydraulic oil tank. Oil must be between marks on the gauge. If necessary, add oil.

8-1 Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve

(4) to bleed air from the hydraulic oil tank.

9. Remove cover (3).

10. Add oil. Recheck oil level gauge.

11. Install cover (3).

M104-07-021

M1J1-07-010

M1J1-07-079

M1J1-07-006

7-31

MAINTENANCE

2

Drain Hydraulic Oil Tank Sump

--- every 250 hours

WARNING: Hydraulic oil may be hot just ater operation. Be sure to wait for oil to cool before starting work.

IMPORTANT: Never run the engine without oil in hydraulic oil tank.

1. Park the machine on a level surface with the upperstructure rotated 90° for easier access.

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. Run the engine at slow idle speed without load for five minutes.

5. Turn the key switch OFF. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Do not loosen the drain plug until oil is cool. Hydraulic oil may be hot, potentially causing serious injury.

7. Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve (1) to bleed air from the hydraulic oil tank.

8. After oil is cool, remove the drain plug (2) and open drain cock (3) to drain water and sediment.

9. After draining water and sediment, tighten drain plug (2) and cock (3) securely.

M1J1-07-006

M1J1-07-037

7-32

MAINTENANCE

3

4

Change Hydraulic Oil

Suction Filter Cleaning

--- every 4000 hours, 2500 hours or 1500 hours

WARNING: Hydraulic oil may be hot. Wait for oil to cool before starting work.

IMPORTANT: Hydraulic oil changing intervals differ according to kind of hydraulic oils used. (See

Recommended Oil Chart in this group)

1. Park the machine on a level surface with the upperstructure rotated 90° for easier access.

2. (Backhoe)

Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended.

3. Lower the bucket to the ground.

4. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Run the engine at slow idle speed without load for five minutes.

6. Stop the engine. Remove the key from the key switch.

7. Pull the pilot control shut-off lever to the LOCK position.

8. Clean the top of the hydraulic oil tank to keep dirt out of the hydraulic system.

9. Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve (6) to bleed air from the hydraulic oil tank.

10. Remove cover (2).

11. Remove oil using a suction pump. The hydraulic oil tank capacity, up to specified oil level, is approximately 560 liter (148 US gal)

12. Remove drain plug (5) and open drain cock (3).

Allow oil to drain.

M104-07-117

M1J1-07-006

M1J1-07-079

M1J1-07-037

7-33

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 14.5 to 19.5 N•m (1.5 to 2.0 kgf•m, 10.5 to 14.5 lbf•ft).

15. Install suction filter and rod assembly (4). Make sure the filter is positioned correctly on the outlet.

16. Clean, install and tighten drain plug (5) and drain cock (3).

925 ± 1.5 mm

157 mm

M1J1-07-060

20 mm

Rod Assembly

M17V-07-069

7-34

MAINTENANCE

17. Install cover (2). After removing cap (1), make sure suction filter and rod assembly (4) is in correct position.

Tighten the bolts to 50 N•m (5.1 kgf•m, 37 lbf•ft).

18. Add oil until it is between the marks on the sight gauge.

IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started.

19. Loosen plug (8) on the top of the pump.

20. Fill the pump with oil through plug (8) port.

21. Retighten the plug.

22. Start the engine and run at slow idle. Put a “Do Not Operate” tag on the pilot control shut-off lever. Make sure the pilot control shut-off lever is in the LOCK position.

23. Slowly loosen plug (7) to release trapped air. Retighten the plug when air stops and oil flows from the plug.

24. Loosen port (7) on the top of hydraulic fan pump. Purge air from the hydraulic pump and fill the pump with oil through the port.

25. After filling the pump with oil, retighten the port. Then, start the engine and run at slow idle.

26. Slowly loosen port (7) to release trapped air. Retighten the plug when air stops and oil flows from the plug.

27. Purge air from the hydraulic system by running the engine at slow idle and operating all control levers slowly and smoothly for 15 minutes.

28. Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended.

29. Lower the bucket to the ground.

30. Turn the auto-idle switch off.

31. Stop the engine. Remove the key from the key switch.

32. Pull the pilot control shut-off lever to the LOCK position.

33. Check the oil level gauge. Remove cover (2) to add oil if necessary.

Engine

Main Pump

M1J1-07-075

Engine

Fan Pump

M1J1-07-076

7-35

MAINTENANCE

5

Replace Hydraulic Oil Tank Filter

--- every 1000 hours

WARNING: Hydraulic oil may be hot just ater operation. 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. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

4. Run the engine at slow idle speed without load for five minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

7. Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve (8) to bleed air from the hydraulic oil tank.

NOTE: There is spring tension under the cover. Hold down the cover when removing last two bolts.

8. Hold down filter cover (2) against light spring load when removing the last two bolts (1). Remove filter cover (2).

9. Remove spring (4), valve (5) and element (6).

10. Discard element (6) and O-ring (3).

11. Install a new element (6), valve (5) and spring (4). And check surely that rubber (7) is installed.

12. Install cover (2) with new O-ring (3).

13. Install and tighten bolts (1) to 50 N•m (5.1 kgf•m, 37 lbf• ft).

14. After replacing the filter element, bleed air from the pump and check the oil level in the hydraulic oil tank.

(Refer to the Bleed Air from Hydraulic System in Step 3.) If the machine is operated with air remaining in the hydraulic system, damage to the hydraulic pump may result.

15. Replace the element at the regular interval to keep hydraulic oil clean and to extend the life of the hydraulic components.

1 2

M104-07-021

M1J1-07-006

M111-07-040

7-36

MAINTENANCE

6

Replace Pump Drain Filter

--- every 1000 hours

WARNING: Hydraulic oil may be hot just ater operation. 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. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

4. Run the engine at slow idle speed without load for five minutes.

5. Stop the engine. Remove the key from the key switch.

6. Operate the right and left control levers to release pressure from the pilot accumulator.

7. Pull the pilot control shut-off lever to the LOCK position.

8. Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve (1) to bleed air from the hydraulic oil tank.

9. Remove filter cartridge (2) by turning it counterclockwise with filter wrench.

10. Clean the filter gasket contact area.

11. Apply a thin film of clean oil to the gasket of new filter.

12. Install the new filter. Turn filter cartridge clockwise by hand until gasket touches contact area. Be sure not to damage gasket when installing filter.

13. Tighten filter cartridge (2) 1/2 turn more using wrench.

14. Start the engine. Check for any leakage.

15. After replacing the filter element, bleed air from the pump and check the oil level in the hydraulic oil tank.

(Refer to the Bleed Air from Hydraulic System in Step 3.) If the machine is operated with air remaining in the hydraulic system, damage to the hydraulic pump may result.

16. Replace the element at the regular interval to keep hydraulic oil clean and to extend the life of the hydraulic components.

M104-07-021

M1J1-07-006

M1J1-07-010

7-37

MAINTENANCE

7 Replace Pilot Oil Filter

--- every 1000 hours

WARNING: Hydraulic oil may be hot just ater operation. 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. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

4. Run the engine at slow idle speed without load for five minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

WARNING: The hydraulic oil tank is pressurized. Push the pressure release button on the air breather before removing the air breather.

7. Remove the filter cartridge of pilot oil filter (2) by turning it counterclockwise with the filter wrench.

8. Clean the filter o-ring contact area on the filter head (1).

9. Apply a thin film of clean oil to the gasket of the new filter.

10. Install new filter. Turn the filter cartridge clockwise by hand until the o-ring touches the contact area. Be sure not to damage the o-ring when installing the filter.

NOTE: Do not re-use the filter cartridge.

M1J1-07-009

M1U1-07-050

7-38

MAINTENANCE

8 Replace Air Breather Element

--- every 4000 hours

WARNING: Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for oil to cool before starting work.

Replacement Procedures

1. Park the machine on solid and level ground. Fully extend the bucket cylinder, fully retract the arm cylinder, and lower the bucket to the ground as illustrated to the right.

Stop the engine.

2. Before replacing the element, be sure to bleed air pressure from the hydraulic oil tank by pressing the air bleed valve on the hydraulic oil tank.

3. Turn cover (2) clockwise about 1/4 turn. Turn cap (1) counterclockwise to remove it.

4. Turn cover (2) counterclockwise to remove it. Then, remove element (3).

5. Install new element (3). Tighten to install cover (2) until cover (2) comes in contact with the element. Then, further tighten the cover 1/4 turn.

6. Securely tighten cap (1) clockwise by hand. While holding cap (1) by hand so that cap (1) does not rotate, securely tighten cover (2) by rotating counterclockwise 5 to 10° by hand.

7. Take care never to allow water and/or contaminant to stay between cover (2) and body (4) (air breathing port).

8. Replace the element periodically to keep hydraulic oil clean and to extend hydraulic components service life.

M104-07-021

M1J1-07-079

M1G6-07-001

7-39

MAINTENANCE

9 Check Hoses and Lines

--- daily

--- every 250 hours

WARNING: Escaping fluid under pressure can penetrate 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-pressure fluids.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

WARNING: Hydraulic oil and lubricant leaks can lead to fire that may result in serious injury.

To avoid this hazard :

• Park the machine on a firm, level surface.

Lower the bucket to the ground.

Stop the engine. Remove key from the key switch.

Pull the pilot control shut-off lever to the LOCK position.

• Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damaged oil cooler, and loose oil cooler flange bolts, for leaks.

Check hoses, lines and oil cooler at the check points indicated below for leaks and other damage that may result in future leaks.

If any abnormalities are found, replace or retighten them, as shown in Tables 1-3.

• Tighten, repair or replace any missing, loose or damaged clamps, hoses, lines, oil cooler, and loose oil cooler flange bolts.

Do not bend or strike high-pressure lines.

Never install bent or damaged hoses or lines.

SA-031

SA-292

SA-044

7-40

Interval(hours) Check Points

Daily Hose covers

Hose ends

Fittings

Every 250 hours

Hose covers

Hose ends

Hose

MAINTENANCE

Table 1. Hoses

Abnormalities

Leak (1)

Leak (2)

Leak (3)

Crack (4)

Crack (5)

Remedies

Replace

Retighten or replace hose or O-ring

Replace

Hose covers

Exposed reinforcement (6)

Blister (7)

Replace

Bend (8) Replace

Hose Collapse (9) Replace

(Use proper bend radius)

Hose ends and fittings

Deformation or

Corrosion (10)

Replace

NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts.

3 2

M137-07-008

M115-07-145

M115-07-146

M115-07-147

M115-07-148

Fig.1

M115-07-149

7-41

MAINTENANCE

Interval(hours)

Daily

Check Points flange joints

Table 2. Lines

Contact surfaces of

Abnormalities

Leak (11)

Remedies

Replace

O-ring and/or retighten bolts

Every 250 hours

Welded surfaces on joints

Joint neck

Welded surfaces on joints

Clamps

Leak (12)

Crack (13)

Crack (12)

Missing

Deformation

Loose

Replace

Retighten

NOTE: Refer to the illustrations in Fig.2 for each check point location or for a description of the abnormality. Use genuine Hitachi parts

Fig.2

M137-07-001

M137-07-007

Interval(hours)

Every 250 hours flange joints

Table 3. Oil cooler

Check Points

Contact surfaces of

Abnormalities

Leak (14)

Oil cooler

Coupling and rubber hose

Leak (15)

Leak (16)

NOTE: Refer to the illustrations in Fig.3 for each check point location.

Remedies

Replace

O-ring and/or retighten bolts

Replace

Retighten or replace

Fig.3

M1J1-07-061

7-42

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.

2. Replace O-ring (1) with a new one when assembling fittings.

3. Lubricate O-ring (1) and install it into groove (3) using petroleum jelly to hold it in place.

4. Tighten fitting (2) by hand, pressing the fitting joint together to ensure O-ring (1) remains in place and is not damaged.

5. Tighten fitting (2) or nut (4) to the torque values shown.

Do not allow hose (5) to twist when tightening fittings.

6. Check for leaks. If oil leaks from a loose connection, do not tighten fitting (2). Open the connection, replace

O-ring (1) and check for correct O-ring position before tightening the connection.

Torque specifications ±10%

Width across flats

(mm)

Fastening torque

27 32 36 41,46 50

N•m 93 137 175 205 255

(kgf•m) (9.5) (14) (18) (21) (26)

(lbf•ft) (69) (101) (130) (152) (188)

2 6 1 4

M104-07-033

7-43

MAINTENANCE

Metal Face Seal Fittings

Fittings are used on smaller hoses and consist of a metal flare and a metal flare seat.

1. Inspect flare (10) and flare seat (9). They must be free of dirt or obvious defects.

IMPORTANT: Defects in the tube flare cannot be repaired.

Overtightening a defective flare fitting will not stop a leak.

2. Tighten fitting (7) by hand.

3. Tighten fitting (7) or nut (8) to the torque values shown.

Do not allow hose (5) to twist when tightening fittings.

Width across flats (mm)

Fastening torque

N•m

(kgf•m)

(lbf•ft)

29.5

(3)

(21.5)

(4)

(29)

(9.5)

(69)

9 8 10 5

M202-07-051

7-44

MAINTENANCE

E. FUEL SYSTEM

Parts

1. Drain Fuel Tank Sump

2. Check Water Separator

3. Replace Main Fuel Filter

4. Replace Fuel Pre-Filter

5. Clean Feed Pump Strainer

6. Check Fuel

Hoses for leaks.

for cracks, bend, etc.

Quantity

—

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 engine is not properly shut down.

4. Run the engine at slow idle speed without load for five minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

WARNING: Handle fuel carefully. Shut the engine off before fueling. Do not smoke while you fill the fuel tank or work on fuel system.

7. Check fuel level gauge (1) or the monitor panel. Add fuel if necessary.

IMPORTANT: Keep all dirt, dust, water and other foreign materials out of the fuel system.

Tank capacity 725 liter (172 US gal)

Interval (hours)

100 250 500 1000 2000

M1J1-01-007

7-45

MAINTENANCE

8. To avoid condensation, fill the tank at the end of each day’s operation. Take care not to spill fuel on the machine or ground. Fuel tank capacity is 725 liters (192 US gal).

Do not fill the tank more than specified. Stop filling when a yellow mark on fuel level gauge (3) becomes visible. Be sure to position the fuel service nozzle so that any part of the nozzle does not obstruct rising of the float-type fuel level gauge (3).

9. Reinstall filter cap (2) on the filler tube. Be sure to lock filter cap (2) with the key to prevent the cap from being lost as well as to prevent vandalism.

NOTE: Take precautions for Fueling with Automatic Fueling

Device (Optional).

Avoid overfilling. Never fail to remove filler cap (2) when refueling with the automatic fueling device and be sure to stop fueling when the yellow mark on the float becomes visible.

Yellow

Mark

1 Drain Fuel Tank Sump --- daily

1. Park the machine on a level surface with the upperstructure rotated 90° for easier access.

2. Lower the bucket to the ground.

3. Turn the auto-idle off.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

4. Run the engine at slow idle speed without load for five minutes.

5. Turn the key switch OFF. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

NOTE: The plug is installed in the drain cock to prevent vandalism.

7. Remove plug (2) and open drain cock (1) for several seconds to drain water and sediment. Close the drain cock.

8. Install and tighten the plug.

7-46

M1J1-07-016

M157-07-060

M1J1-07-029

MAINTENANCE

2 Check Water Separator

--- daily (Before staring operation)

Water separator separates any water that may get mixed with the fuel. Water separator contains a float which rises as water accumulates.

Be sure to drain the sediment when the float rises up to the

“Drain Water” mark written on the outside of water separator .

IMPORTANT: If the fuel contains an excessive amount of water, shorten the interval between water separator checks.

Draining Procedures (Main Filter)

1. Place 0.5 liters (0.5 US qt) or larger capacity container under drain plug (3) to collect the drained water.

2. Shut off the fuel supply by closing cock on the bottom of the fuel tank.

3. Loosen plug (1) on the top of the fuel main filter.

4. Rotate drain plug (3) on the bottom of the filter about

4-turns counterclockwise to drain the water accumulated in the filter.

5. After draining water, securely tighten drain plug (3) and plug (1). Return fuel cock to the original position.

6. Start the engine. Check drain plug (3) and plug (1) for fuel leaks.

Wrench size: 10 mm

Main Filter

M1J1-07-002

Main Filter

M1GR-07-010

M1GR-07-002

7-47

MAINTENANCE

Draining Procedures (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. Shut off the fuel supply by closing cock on the bottom of the fuel tank.

3. Loosen plug (4) on the top of the fuel pre-filter.

4. Rotate drain plug (5) counterclockwise to completely drain water.

5. After draining water, securely tighten drain plug (5) and plug (4). Return fuel cock to the original position.

6. Start the engine. Check drain plug (5) and plug (4) for fuel leaks.

NOTE: After draining water mixed in fuel, bleed air from the fuel supply system.

Wrench size: 14 mm

Pre-Filter

M1J1-07-047

M1U1-07-004

M1U1-07-005

7-48

MAINTENANCE

Fuel cock

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 water separator, replacing the fuel filter, cleaning the fuel solenoid pump strainer or running the fuel tank dry, be sure to bleed the air from the fuel system.

WARNING: Fuel leaks may lead to fires.

1. Check that fuel cock on the bottom of the fuel tank is opened.

2. Loosen air bleed plug (2) on the fuel main filter (3).

3. Supply fuel by reciprocating priming pump (6). After no air bubbles are spouted through air bleed plug (2), lock the priming pump (6).

4. Supply fuel by reciprocating priming pump (1) of main filter (3), bleed the remained air.

5. Tighten air bleed plug (2) of main filter (3)

CAUTION: Bleed air from main filter (3) one by one.

IMPORTANT: Over tightening air bleed plug (2)causes damage.

6. Loose air breather plug (5) of fuel feed pump (4). Supply fuel by reciprocating priming pump (6) of fuel feed pump

(4), bleed the remained air.

7. Tighten air bleed plug (5) of fuel feed pump (4)

IMPORTANT: Do not over tighten air bleed plug (5).

8. After tightening air bleed plug (1), reciprocate priming pump (6) approx. 150 strokes.

9. Wipe off any spilled fuel.

10. Start the engine. Check that no fuel leaks are present. If the engine does not start, repeat the above procedures from step 1.

Wrench size: 10 mm

M1J1-07-029

M1J1-07-062

M1J1-07-063

7-49

MAINTENANCE

3 REPLACE FUEL MAIN FILTER ELEMENT

--- every 500 hours

IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel cartridge and the precartridge. 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’ elements are excluded from Hitachi Warranty Policy.

Procedures:

1. Close cock (5) on the bottom of the fuel tank.

2. Place a 1-liter (1 US qt) or larger capacity drain container under drain plug (2).

3. Loosen air bleed plug (1) and drain plug (2). Drain fuel until fuel does not flow out of the filter.

4. Remove transparent filter case (7) using the exclusive tool.

5. When transparent filter case (7) is removed, the element is exposed. Remove the element by hand.

6. Install a new element. Tighten transparent filter case (7) to 29.4 ± 2 N•m (3±0.2 kgf•m, 21.7±1.4 lbf•ft) using the exclusive tool.

7. Tighten air bleed plug (1) and drain plug (2).

8. Open cock (5) on the bottom of the fuel tank.

9. Bleed air from the fuel supply system.

After replacing the fuel filter element, bleed air from the fuel supply system. (Refer to the air bleed procedures described on page 7-49.)

Wrench size: 10 mm

Main Filter

M1J1-07-029

M1J1-07-002

Main Filter

M1GR-07-010

M1GR-07-002

7-50

MAINTENANCE

4 REPLACE FUEL PRE-FILTER ELEMENT

--- every 500 hours

Procedures:

1. Close cock (5) on the bottom of the fuel tank.

2. Place a 1-liter (1 US qt) or larger capacity container under drain plug (1).

3. Loosen air bleed plug (4) and drain plug (1). Drain fuel until fuel does not flow out of the filter.

4. Remove transparent filter case (8) using an exclusive tool.

5. When transparent filter case (8) is removed, the element is exposed. Remove the element by hand.

6. Install a new element. Tighten transparent filter case (8) to 30 ± 2 N•m (3±0.2 kgf•m, 22±1.4 lbf•ft) using the exclusive tool.

7. Tighten air bleed plug (4) and drain plug (1).

8. Open cock (5) on the bottom of the fuel tank.

9. Bleed air from the fuel supply system.

After replacing the fuel filter element, bleed air from the fuel supply system. (Refer to the air bleed procedures described on page 7-49.)

Wrench size: 14 mm

M1J1-07-054

Fuel Pre-ﬁlte

M1J1-07-047

M1U1-07-004

M1U1-07-005

7-51

MAINTENANCE

5 Clean Feed Pump Strainer

--- every 500 hours

1. Remove the feed pump (2) inlet hose joint bolt (1), located at the water separator inlet.

2. Remove strainer (3) from joint bolt (1) using a screw driver.

3. Clean strainer (3) using diesel fuel.

4. Install and tighten strainer (3) in joint bolt (1).

5. Install and tighten joint bolt (1).

6. After replacing for filter, bleed air from the fuel system.

M157-07-191

2 1

M1JB-07-039

7-52

MAINTENANCE

6 Check Fuel Hoses

--- daily

--- every 250 hours

WARNING: Fuel leaks can lead to fires that may result in serious injury.

To avoid this hazard :

1. Park the machine on a firm, level surface. Lower the bucket to the ground. Stop the engine. Remove key from the key switch. Pull the pilot control shut-off lever to the

LOCK position.

2. Check for kinked hoses, and hoses that rub against each other parts for leaks.

Check hoses at the check points indicated below for leaks and other damage that may result in future leaks. If any abnormalities are found, replace or retighten them, as shown in Table 4.

3. Repair or replace any loose or damaged hoses. Never install bent or damaged hoses.

Interval(hours)

Daily

Check Points

Hose ends

Surface braid hose

Every 250 hours Surface braid hose

Hose ends

Table 4. Hoses

Abnormalities

Leak (1)

Friction (2)

Crack (2)

Crack (3)

Crack (4)

Remedies

Retighten or replace

Replace

Hose Bend (5) Replace

Hose Collapse (6) Replace

(Use proper bend radius)

Hose ends and fittings Deformation or

Corrosion (7)

Replace

NOTE: Refer to the illustrations in Fig.1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts.

SA-019

M137-07-003

M137-07-004

M137-07-005

M137-07-006

Fig. 1

7-53

MAINTENANCE

F. AIR CLEANER

Parts

1. Air Cleaner Outer Element

2. Air Cleaner Inner Element

Cleaning

Replacement

Quantity

1 Clean the Air Cleaner Outer Element

--- every 250 hours or when the restriction indicator comes ON

2 Replace the Air Cleaner Outer and Inner

Elements

--- after cleaning six times or after one year

10 50

Interval (hours)

100 250 500 1000 2000

(Or when indicator lit)

After cleaning 6 times or 1 year

When outer element is replaced

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. Run the engine at slow idle speed without load for five minutes.

5. Stop the engine. Remove the key from the key switch.

6. Pull the pilot control shut-off lever to the LOCK position.

7. Loosen butterfly nut (2) to remove cover (1).

8. Clean cover (1) interior.

9. Loosen butterfly nut (4) to remove outer element (3).

WARNING: Use reduced compressed air pressure.

Clear area of bystanders, guard against flying chips, and wear personal protection equipment including goggles or safety glasses.

10. Clean outer element (3) using compressed air. Direct the air to the inside of the filter element, blowing out.

M1J1-07-003

M1J1-07-038

M1J1-07-005

7-54

MAINTENANCE

11. Clean the filter interior before installing outer element (3).

12. Install outer element (3). While slightly pushing outer element (3) into the body to hold it in place.

13. Install cover (1) and tighten butterfly nut (2).

14. Start the engine and run at slow idle.

15. Check the air filter restriction indicator on the monitor panel. If the air filter restriction indicator comes ON, stop the engine and replace outer element (3).

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).

17. Clean body (7) interior, every 250 hours or when air filter restriction indicator comes on.

NOTE: When installing outer element (3), insert outer element

(3) so that outer element (3) aligns with the groove on body (7). If inserted without aligning with the groove, the element may become difficult to remove.

M1J1-07-005

7-55

MAINTENANCE

G. COOLING SYSTEM

Parts Quantity

10 50

Interval (hours)

100 250 500 1000 2000

1. Check Coolant Level

2. Change Coolant

3. Clean Radiator, Oil Cooler, Inter Cooler, Fuel Cooler Core

4. Clean Oil Cooler Front Screen

Outside

Inside

55 L (14.5 US gal)

Twice a year ✸

Once a year

★

NOTE: ★ Shorten maintenance interval when the machine is operated in dusty areas.

✸

When genuine Hitachi coolant is used, replace every two years or 4000 operating hours, whichever comes first.

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.

Antifreeze

If the air temperature is expected to fall below 0°C (32°F), fill the cooling system with an antifreeze and soft water mix. As a general rule, the ratio of antifreeze should range between

30% and 60% as shown in the table below. If the ratio is below 30%, the system may develop rust, and if it is above

60%, the engine may overheat.

7-56

Air temperature

°C

–1

–4

–7

–11

–15

–20

–25

–33

°F

–4

–13

–27

Mixing ratio

WARNING:

• Antifreeze is poisonous; if ingested, it can cause serious injury or death. Induce vomiting and get emergency medical attention immediately.

• When storing antifreeze, be sure to keep it in a clearly marked container with a tight lid. Always keep antifreeze out of the reach of children.

• If antifreeze is accidentally splashed into eyes, flush with water for 10 to 15 minutes and get emergency medical attention.

• When storing or disposing of antifreeze, be sure to comply with all local regulations.

MAINTENANCE

Antifreeze Mixing Table

Refill capacities

Antifreezes liters

16.5

19.3

22.0

24.8

27.5

US gal

4.36

5.10

5.81

6.55

7.27

liters

38.5

35.7

33.0

30.2

27.5

Soft water

US gal

10.17

9.43

8.72

7.98

7.27

7-57

MAINTENANCE

1 Check Coolant Level --- daily

WARNING: Do not loosen radiator filler cap (1) unless the system is cool. Loosen the cap slowly to the stop.

Release all pressure before removing the cap.

With the engine cold, the coolant level must be between the

FULL and LOW marks on coolant reservoir (2), located side of the fuel tank. If the coolant level is below the low mark, add coolant to coolant reservoir (2).

If coolant reservoir (2) is empty, remove cover (3) located on the radiator and add coolant to the radiator and then to coolant reservoir (2).

Radiator Upper Cover

M1J1-07-078

M1J1-07-039

FULL

LOW

M1J1-07-073

7-58

MAINTENANCE

2 Change Coolant

--- twice a year (in spring and autumn)

NOTE: Before leaving the Hitachi Factory, the cooling system is filled with a mixture of water and Genuine Hitachi

Long-Life Coolant.

As long as Genuine Hitachi Long-Life Coolant is used, the service intervals between changing the coolant is once every two years, or every 4000 hours, whichever comes first.

WARNING: Do not loosen the radiator cap until the system is cool. Loosen the cap slowly to the stop. Release all pressure before removing the cap.

1. Remove cover (3) of radiator drain cock.

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; when the needle of the temperature gauge reaches the green zone, run the engine for about ten more minutes.

4. Stop the engine and open drain cock (1). Flush out the cooling system with tap water, until draining water is clear. This helps remove rust and sediment.

5. Close drain cock (1). Fill the radiator with tap water and an anti-rust agent or antifreeze at the specified mixing ratio. When adding coolant, do so slowly to avoid mixing air bubbles in the system.

6. Run the engine to sufficiently bleed the air from the cooling system.

7. After adding coolant, operate the engine for several minutes. Check the coolant level again, and add coolant if necessary.

7-59

SA-039

M1J1-07-028

M1J1-07-027

M1J1-07-044

MAINTENANCE

3 Clean Radiator/ Oil Cooler/ Inter Cooler/ Fuel

Cooler Core

--- every 500 hours

WARNING: Use reduced compressed air pressure for cleaning purposes. Clear the area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

IMPORTANT: If the compressed air [should be less than

0.2 MPa (2 kgf/cm

)] or tap water pressure is high, damage to the radiator / oil cooler fins may result. Keep the nozzle more than 500 mm away from the core surface.

The radiator and the oil cooler are arranged in parallel. And inter cooler is arranged in series. When cleaning the radiator/ oil cooler, open the bracket installed condenser/ fuel cooler. Clean any dust stuck to the core.

Clean the radiator / oil cooler/ inter cooler core using compressed air [less than 0.2 MPa (2 kgf/cm

)] or tap water to prevent the cooling system performance from deteriorating.

Fuel Cooler

4 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.

Bracket Installed

Condenser/Fuel Cooler

Inter Cooler

Radiator

M1J1-07-032

Oil Cooler

M1J1-07-034

Screen

M1J1-07-033

7-60

MAINTENANCE

H. AIR CONDITIONER

Parts

1. Circulating Air Filter

Fresh Air Filter

Cleaning

Replacement

Cleaning

Replacement

2. Check Refrigerant (Gas) Quantity

3. Check Compressor Belt Tension

4. Clean Condenser Core

5. Check Looseness at each of Fastened Areas

6. Check In-Season and Off-Season

Quantity

—

10 50

Interval (hours)

100 250 500 1000 2000

When excessively restricted

Twice a year

7-61

MAINTENANCE

Clean Filter

Circulating Air Filter --- every 250 hours

Fresh Air Filter --- every 250 hours

Replace Filter

Circulating Air Filter --- When excessively restricted

Fresh Air Filter --- every 1000 hours

Removing Fresh Air Filter

1. Insert the key into keyhole (2) on left cab side cover (1).

Then, rotate the key counterclockwise to unlock the key.

Open cover (1).

2. While pressing knobs (4) on both sides of fresh air filter (3) inward, horizontally remove the fresh air filter.

M1U1-07-010

Removing Recirculation Filter

1. Recirculation filter (5) is located under the rear deck.

2. Holding grips (6), pull them toward you to remove.

M1U1-07-011

M1U1-07-012

7-62

MAINTENANCE

WARNING: Use reduced compressed air pressure (less than 0.2 MPa, 2 kgf/cm

) for cleaning purposes. Clear the area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

Cleaning

Clean both the external and internal filters by blowing compressed air or washing with water.

When washing the filters with water, follow the procedures below:

1. Wash with tap water.

2. Soak the filters in neutral detergent-mixed water for approx. 5 minutes.

3. Wash the filters with water again.

4. Dry the filters.

Rear Side of Cab

Installation

When installing the cleaned recirculation and/or ventilation filter or new filters, follow the reverse order of the Removing

Filter procedures described on the front page.

• Ventilation Filter

Use attention when installing the filter so that the notch faces the back of the cab and the stamped arrows face the air conditioner unit. After installing the filter, install the upper cover while aligning it with the duct.

• Recirculation Filter

While contacting the attached filter plate onto the duct, install the filter so that the clips align with the duct mounting holes.

Support

Air Conditioner Side

M1U1-07-013

M1U1-07-012

7-63

MAINTENANCE

2 Check Refrigerant (Gas) Quantity

--- every 250 hours

WARNING: DO NOT allow liquid refrigerant to contact eye or skin. Liquid refrigerant will freeze eye or skin on contact. Be careful not to loosen connections in the air conditioning circuit.

Insufficient refrigerant quantity will reduce cooling capacity of the air conditioner. Check quantity via sight glass (2) provided on receiver tank (1).

Inspection Procedure

1. Start the engine and run at approximately 1500 min

−1

(rpm).

2. Turn the air conditioner switch to ON.

3. Set the blower switch to HI.

4. Set the temperature control switch to the coolest position.

5. Check refrigerant quantity through a sight glass on the receiver tank.

NOTE: If a sign of oil oozing out of the pipe joint is found, the refrigerant may be leaking.

If the refrigerant level is low, consult your authorized dealer.

3 Check Compressor Belt Tension

--- every 250 hours

Visually check belt for wear. Replace if necessary. Check belt tension by depressing the midpoint between the crank and idle pulleys with the thumb. Deflection must be 6 to 10 mm

(0.24 to 0.39 in.) at a depressing force of approximately 98 N (10 kgf, 22 lbf).

If tension is not within specifications, loosen the bolts for the idle pulley mounting bracket to adjust belt tension.

NOTE: When a new belt is installed, be sure to re-adjust the tension after operating the engine for 3 to 5 minutes at slow idle speed to be sure that the new belt is seated correctly.

No Refrigerant

Empty

Push

(about 98N, 10kgf)

Crank Pulley

M1J1-07-035

Suﬃcient

Quantity

Almost clear. A few bubbles may appear when the engine speed is raised or lowered

Idle Pulley

Compressor Pulley

M107-01-010

Deﬂection

6 to 10 mm

(0.24 to 0.39 in)

M1J1-07-064

7-64

MAINTENANCE

4 Clean Condenser Core

--- every 500 hours

WARNING: Always wear safety glasses or goggles when using compressed air to clean condenser core.

IMPORTANT: High-pressure air or water can damage condenser fins.

Condenser is located in front of the oil cooler. Clean the condenser core with water or steam.

5 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:

Wrench Size

(mm)

Tightening Torque

N•m (kgf•m) (lbf•ft)

14.5 to 19.5

(1.5 to 2.0) (10.5 to 14.5)

24.5 to 29.5

(2.5 to 3.0) (18.0 to 21.5)

29.5 to 34.0

(3.0 to 3.5) (21.5 to 25.5)

M1J1-07-032

7-65

MAINTENANCE

6 Check In-Season and Off-Season

--- twice a year

WARNING: Do not attempt to loosen connections in air conditioning circuit when the air conditioner malfunctions. Doing so may cause high pressure gas to spout, resulting in serious injury. Consult your authorized dealer immediately.

1. Preseason maintenance

Prior to the season, consult your authorized dealer for maintenance of the air conditioner in order to operate it in good condition during the season.

This maintenance includes replenishment of refrigerant, inspection and replacing (if necessary) of inner and outer air filters, line connections, pressure switches and inspection and cleaning of evaporator.

2. Off-season maintenance

(1) Operate the compressor once a week at low speed for several minutes in order to maintain its parts in well lubricated condition. Be sure to run the engine at slow idle and place the temperature control switch in MEDIUM COOL. This operation also revents refrigerant leakage caused by dried up shaft seal.

(2) Check for refrigerant leakage. If the refrigerant level is low during off-season, rust will be formed inside the circuit.

NOTE: Do not remove V-belt from the compressor during offseason.

7-66

MAINTENANCE

I. ELECTRICAL SYSTEM

1. Battery

2. Replace Fuse

Parts

Level Check

Specific Gravity

Replacement

Quantity

—

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 equipment’ s may cause machine failure and/or a fire on the machine.

Be sure to consult your authorized dealer when installing a radio communication equipment or additional electrical parts, or when replacing electrical parts.

Never attempt to disassemble or modify the electrical/electronic components. If replacement or modification of such components is required, contact your authorized dealer.

10 50

Interval (hours)

100 250 500 1000 2000

Every month

As required

7-67

MAINTENANCE

1 Batteries

WARNING: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check the battery electrolyte level.

Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into the eyes.

Batteries are installed in the front right cover.

Avoid hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Using proper booster battery starting procedures.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. If splashed in eyes, flush with water for 10 to 15 minutes. Get medical attention immediately.

SA-032

SA-036

Batteries Location M1J1-07-014

7-68

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.

IMPORTANT: If the battery is used with the electrolyte level lower than the specified lower level, the battery may deteriorate quickly.

IMPORTANT: Do not refill electrolyte more than the specified upper level. Electrolyte may spill, damaging the painted surfaces and/or corroding other machine parts.

NOTE: In case electrolyte is refilled more than the specified upper level line or beyond the bottom end of the sleeve, remove the excess electrolyte until the electrolyte level is down to the bottom end of the sleeve using a pipette.

After neutralizing the removed electrolyte with sodium bicarbonate, flush it with plenty of water, otherwise, consult the battery manufacturer.

7-69

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. Do not use a dry towel. Static electricity may be developed, causing the battery gas to explode. Check if the electrolyte level is between U.L (Upper Level) and L.L (Lower

Level). In case the electrolyte level is lower than the middle level between the U.L and L.L, immediately refill distilled water or commercial battery fluid. Be sure to refill with distilled water before recharging (operating the machine). After refilling, securely tighten the filler plug.

3.2 When impossible to check the level from the battery side or no level check mark is indicated on the side:

After removing the filler plug from the top of the battery. Check the electrolyte level by viewing through the filler port. It is difficult to judge the accurate electrolyte level in this case. Therefore, when the electrolyte level is flush with the U.L, the level is judged to be proper. Then, referring to the right illustrations, check the level. When the electrolyte level is lower than the bottom end of the sleeve, refill with distilled water or commercial battery fluid up to the bottom end of the sleeve. Be sure to refill with distilled water before recharging (operating the machine). After refilling, securely tighten the filler plug.

3.3 When an indicator is available to check the level, follow its check result.

4. Always keep around the battery terminals clean to prevent battery discharge. Check terminals for loose and/or rust. Coat terminals with grease or petroleum jelly to prevent corrosion build up.

Filler Port

U.L (Upper Level)

L.L (Lower Level)

M146-07-109

Sleeve

Upper Level

Lower Level

Separator Top

M146-07-110

Proper

Lower

Since the electrolyte surface touches the bottom end of the sleeve, the electrolyte surface is raised due to surface tension so that the electrode ends are seen curved.

M146-07-111

When the electrolyte surface is lower than the bottom end of the sleeve, the electrode ends are seen straight.

M146-07-112

M409-07-072

7-70

MAINTENANCE

Check electrolyte specific gravity

WARNING: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check the battery electrolyte level.

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into the eyes.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. If splashed in eyes, flush with water for 10 to

15 minutes. Get medical attention immediately.

Never check the battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove the grounded (−) battery clamp first and replace it last.

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.

Avoid hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Using proper booster battery starting procedures.

IMPORTANT: Check the specific gravity of the electrolyte after it is cooled, not immediately after operation.

Check the electrolyte specific gravity in each battery cell.

The lowest limit of the specific gravity for the electrolyte varies depending on electrolyte temperature.

The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit.

Recommended range of speciﬁc gravity by electrolyte temperature

Fluid temp.

40°C

(104°F)

20°C

(68°F)

0°C

(32°F)

–20°C

(–4°F)

–40°C

(–40°F)

1.21

Working Range

1.22

1.23

1.24

1.25

1.26

1.27

1.28

1.29

1.30

1.31

1.32

Speciﬁc gravity of battery ﬂuid

M104-07-054

REPLACE BATTERIES

Your machine has two 12-volt batteries with negative (−) ground.

If one battery in a 24-volt system has failed but the other is still good, replace the failed battery with one of the same type. For example, replace a failed maintenance-free battery with a new maintenance-free battery. Different types of batteries may have different rates of charge. This difference could overload one of the batteries and cause it to fail.

7-71

MAINTENANCE

If any electrical equipment fails to operate, first check the fuses. Fuse box is located behind the operator’s seat. A fuse location/specification decal is attached to the fuse box cover.

Remove the fuse box cover by lifting it upward. Spare fuses are located on the underside of the cover.

IMPORTANT: Be sure to install fuses with correct amperage ratings to prevent electrical system damage due to overload.

FUSE BOX

10- CONTROLLER

9- BACKUP

10A

8- ECM

30A

7- LUBRICATOR

10A

6- OPTION2

10A

5- OPTION1

4- SOLENOID

10A

3- HEATER

20A

2- WIPER

10A

1- LAMP

20A

20- OPTION3

19- SW. BOX

18- POWER ON

17- AIRCON

16- GLOW. R

15- AUXILIARY

10A

14- PCV

15A

13- LIGHTER

10A

12- ROOM LAMP/RADIO

11- HORN

10A

ADDITIONAL FUSE BOX

30- AUTO LUB.

10A

29- LIGHT1

10A

28- SPARE

40- SPARE

39- SPARE

38- SPARE

27- AUXILIARY3

26- QYICK HITCH

25- IMOBI

24- 12V UNIT

10A

23- CAB LAMP REAR

10A

22- CAB LAMP FRONT

10A

21- SEAT HEATER

10A

37- SPARE

36- SPARE

35- SPARE

34- AUXILIARY2

10A

33- WARNING LAMP

10A

32- CAB LAMP FRONT+2

10A

31- SEAT COMPR.

10A

7-72

Fuse Box Additional Fuse Box

M1J1-01-021

M1GR-01-003

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. Replace it if blown.

21- + Side (Red) 45A

22- – Side (Black) 75A

M1J1-07-015

7-73

MAINTENANCE

J. MISCELLANEOUS

Parts Quantity

1. Check Bucket Teeth for Wear and Looseness

2. Change Bucket

3. Adjust Bucket Linkage

4. Remove Travel Levers

5. Check and Replace Seat Belt

6. Check Windshield Washer Fluid Level

7. Check Track Sag

8. Clean Cab Floor

9. Check Tightening Torque of Bolts and Nuts

10. Check O-rings in Bucket Joints

11. Retighten Cylinder Head Bold

12. Inspect and Adjust Valve Clearance

13. Check fuel Injection Timing

14. Measure Engine Compression Pressure

15. Check Starter and Alternator

16. Check Water Pump

—

NOTE: ★ First time only.

✹

Contract your authorized dealer for maintenance.

Interval (hours)

10 50 100 250 500 1000 2000 4000

As required

Every 3 years (Replace)

As required

★

✹

As required

✹

As required

✹

3

10

1

⎭

⎬

⎫

2

4

8

5

6

7

7-74

⎫ ⎪

⎪ ⎪

⎬ ⎪

9

⎪ ⎪

⎭

11 12 13

14 15 16

M1J1-01-001

MAINTENANCE

1 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)

New Limit of Use Parts No.

Standard 254 (10.0“) 120 (4.7“)

Rock Bucket 280 (11.0“) 140 (5.5“)

4471407

4350781

NOTE: When tooth point (1) is used in excess of the service limit, a hole will be made on the tooth point, which makes the nose exposed and worn out, and will eventually break or let the tooth point fall off.

2. Replacement

WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses.

(1) Removing the tooth point

(a) Preparations for removing tooth point.

Hit the left and right top ends and the left and right lugs of tooth point (1) alternately with hammer to knock off pebbles, soil, etc., stuck in the gap between tooth point (1) and adapter (2).

(b) Inserting lock removal tool.

Remove pebbles, dirt, etc., completely from the gap between lock pin (3) and adapter (2). Place pin-removing jig on the top end of lock pin (3) and hit it with hammer to remove lock pin (3).

When driving out the pin, first hit with a shorter jig until top end of lock pin (3) comes to the upper end position of the lug of tooth point (1), and then use the longer jig to remove lock pin (3).

M1J1-07-065

M1J1-07-066

M1J1-07-067

M1J1-07-068

7-75

MAINTENANCE

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 the tooth point, be sure to check whether they are usable or not when replacing tooth point (1).

(2) Mounting the tooth point

(a) Mounting the tooth point

Clean the top end of the adapter (2) nose. If pebbles, dirt, etc., are stuck to the adapter nose, tooth point (1) will not insert properly and the pin cannot be driven in.

Also check that lock pin (3) has no cracks.

Insert tooth point (1) slowly until the tooth point comes to the end of the adapter (2) nose while twisting and turning it to the right.

M1J1-07-066

7-76

MAINTENANCE

b. Inserting the pin

(1) Insert lock pin (3) facing toward the adapter nose.

(2) With tooth point (1) fully inserted onto the adapter (2), tap lock pin (3) into the tooth point (1) with a hammer until the top of lock pin (3) comes flat with the nose surface. (i.e. until the lock pin (3) fits into the grooves of tooth point (1).)

M1J1-07-070

NOTE: (1) Since rubber is susceptible to corrosion, do not use grease, oil and other oily materials when inserting the lock pin (3).

(2) In mounting welding-type nose and adapter (2) onto the bucket, the lock pin (3) should be removed from the nose when preheating and welding. Otherwise, the rubber will be spoiled.

Tooth Side

Upper Side

M1J1-07-071

Adapter

Side

Lower Side

Inserting Direction

M1J1-07-077

7-77

MAINTENANCE

2 Change Bucket

WARNING: When driving the connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses, and safety equipment appropriate to the job.

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. Be sure the bucket will not roll when the pins are removed.

Type A (Separate Type O-ring)

2. Remove o-rings (1) after loosing nut (2).

Type B (Unit Type O-ring)

2. Slide O-rings (3) out of the way, as shown.

3. Remove bucket pins A and B to separate the arm and bucket. Clean the pins and pin bores. Apply sufficient grease to the pins and pin bores.

4. Align the arm and alternate bucket. Be sure the bucket will not roll.

5. Install bucket pins A and B.

6. Install the locking pins and snap ring on pins A and B.

7. Adjust bucket linkage clearance for pins A. See the Adjusting Bucket Linkage procedure on the next page.

Type A (Separate Type O-ring)

8. Tighten nut (2) after installing O-rings (1) on the bucket boss A and B. And cut off the bolt extended from the nut.

Refer to the check O-rings in bucket of Chapter 7.

Type B (Unit Type O-ring)

8. Install O-rings (3) on the bucket boss A and B.

9. Apply grease to pin joints A and B.

10. Start the engine and run at slow idle. Slowly operate the bucket in both directions to check for any interference in bucket movement. Do not operate a machine that has any movement interference. Correct interference problem.

Bucket Boss

Arm

Separation Section

Type A

O-Ring Shift

Type B

Link

M1J1-07-074

Bucket

M104-07-063

7-78

MAINTENANCE

3 Adjust the Bucket Linkage (Backhoe)

When play in the linkage increases, remove and install shims as follows:

1. Park the machine on a level surface. Lower the bucket to the ground with the flat side down so that the bucket will not roll.

2. Run the engine at slow idle. With the bucket on the ground, slowly swing counterclockwise slightly until the top of the left bucket boss contacts the arm.

3. Stop the engine. Pull the pilot control shut-off lever to the LOCK position.

4. Adjust the clearance between arm and bucket to become from 0.5mm to 1mm (0.02 – 0.04 in) by Shims.

Bucket

Clearance

Adjust Part

NOTE: The product is shipped with shims (1mm (0.04 in) : 2 pieces, 1.6mm (0.063 in): 1 piece) from the factory.

Shim

Arm

M104-07-063

M1J1-07-072

7-79

MAINTENANCE

4 Remove the Travel Levers

The travel levers may be removed if desired.

1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Turn the key switch OFF. Remove the key.

5. Pull the pilot control shut-off lever to the LOCK position.

6. Remove bolts (1) and (2) to remove levers (3) and (4) from brackets.

NOTE: Wrench size 17 mm

Tightening torque 50 N•m

(5.1 kgf•m, 37 lbf•ft)

5 Check and Replace Seat Belt

Check --- daily

Replace --- every 3 years

Always maintain the seat belt in a functional condition and replace when necessary to ensure proper performance.

Prior to operating the machine, thoroughly examine belt (5), buckle (6) and attaching hardware (7) and tether belt (8). If any item is damaged or materially worn, replace the seat belt or component before operating the machine.

We recommend that the seat belt be replaced every three years regardless of its apparent condition.

6 Check Windshield Washer Fluid Level

Windshield washer fluid tank (9) is located in the cover after the cab.

Check the windshield washer fluid tank (9) at daily.

If the windshield washer fluid is needed, remove the rubber cap (11)/cap (10) and add the windshield washer fluid.

M178-07-077

M1U1-07-008

M1J1-07-012

7-80

7 Check Track Sag --- every 50 hours

MAINTENANCE

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.

Rotate the raised track in reverse two full rotations and then forward two full rotations.

Measure distance (A) at the middle of the track frame from the bottom of the track frame to the back face of the track shoe.

Model

ZAXIS450

-3

ZAXIS470H

-3

ZAXIS450LC

-3

ZAXIS470LCH

-3

ZAXIS500LC

-3

ZAXIS520LCH

-3

Track Sag Specifications

380 to 430 mm (15.0 to 16.9 in)

390 to 440 mm (15.3 to 17.3 in)

430 to 480 mm (16.9 to 18.9 in)

NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.

Adjust Track Sag

Precautions for Adjusting Track Sag

1. If track sag is not within specifications, loosen or tighten the track following the procedures shown on the next page.

2. When adjusting track sag, lower the bucket to the ground to raise one track off the ground.

Repeat this procedure to raise the other track.

Each time, be sure to place blocks under the machine frame to support the machine.

3. After adjusting track sag of both tracks, move the machine back and forth several times.

4. Check track sag again. If track sag is not within specifications, repeat adjustment until correct sag is obtained.

M104-07-067

M107-07-068

7-81

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.

1. To loosen the track, slowly turn valve (1) counterclockwise using long socket 24; grease will escape from the grease outlet.

2. Between 1 to 1.5 turns of valve (1) is sufficient to loosen the track.

3. If grease does not drain smoothly, slowly rotate the raised track.

4. When proper track sag is obtained, turn valve (1) clockwise and tighten to147 N•m (15 kgf•m, 108 lbf•ft).

Tighten the Track

WARNING: It is abnormal if the track remains tight after turning valve (1) counterclockwise or if the track is still loose after charging grease to fitting (2). In such cases, NEVER ATTEMPT TO DISASSEMBLE the track or track adjuster, because of dangerous high-pressure grease inside the track adjuster. See your authorized dealer immediately.

To tighten the track, connect a grease gun to grease fitting (2) and add grease until the sag is within specifications.

Grease Outlet

Replace the Track

CAUTION: Special training and expertise are needed to replace the track.

NEVER ATTEMPT to replace the track yourself.

Be sure to ask your authorized dealer for track replacement.

M116-07-093

M16J-07-083

7-82

MAINTENANCE

8 Clean Cab Floor --- as necessary

IMPORTANT: When cleaning the cab floor with tap water, spray the floor only. Take care not to splash the surrounding area. Do not increase water spray speed by restricting the hose end, and do not use high pressure steam for cleaning.

Be sure to completely remove any moisture from the surrounding area.

1. Park the machine on solid and level surface. Lower the bucket to the ground. Before cleaning, stop the engine.

2. Sweep the cab floor clean using a brush, and brush dust from the cab floor while spraying water.

3. When cleaning the floor mat, sweep dust (water) along the grooves on the floor mat.

4. When cleaning after removing the floor mat, remove two caps (1) plugging the cleaning holes on the floor plate.

Sweep dust (water) through these cleaning holes.

M1U1-077-052

7-83

MAINTENANCE

9 Check Tightening Torque of Bolts and Nuts

--- every 250 hours (first time after 50 hours)

Check tightness after the first 50 hours then every 250 hours.

Tighten to torque shown if any are loose. Bolts and nuts should be replaced with those of the same or higher grade.

For tightening nuts and bolts other than specified in the table below, refer to the Tightening Torque Chart at the end of this section.

IMPORTANT: Check and tighten bolts and nuts using a torque wrench.

Torque Specifications

No Descriptions

Bolt Dia mm

Engine cushion rubber mounting bolt

Front

Rear

Engine cushion rubber

Cushion rubber-machine 18

2 Engine bracket mounting bolt 14

3 Radiator mounting bolt

4 Hydraulic oil tank mounting bolt

5 Fuel tank mounting bolt 16

Q’ty

6 ORS fittings for hydraulic hoses and piping

7 Pump device mounting bolt

8 Fan pump mounting bolt

9. Fan motor mounting bolt

10 Control valve mounting bolt

11 Control valve bracket mounting bolt

12 Swing device mounting bolt

13 Swing motor mounting bolt (hexagonal wrench)

14 Battery mounting nut

15 Cab mounting nut

16 Cab anchor mounting nut

Swing bearing mounting bolt to upper structure

Swing bearing mounting bolt to undercarriage

Travel device mounting bolt

Travel motor mounting bolt

Sprocket mounting bolt

19 Upper roller mounting bolt

450-3,470H-3,

450LC-3, 470LCH-3

500LC-3, 520LCH-3

NOTE: ★ Hexagonal socket wrench

★

Wrench

Size (mm)

210

230

110

400

750

300

210

550

1950

1400

750

300

750

400

550

N•m

1050

750

400

210

550

210

180

(21.5)

(9.0)

(23.5)

(11.0)

(41.0)

(76.5)

(30.5)

(3.5)

(21.5)

(56.0)

(199)

(143)

(76.5)

(30.5)

(76.5)

(41.0)

(56.0)

Torque

(kgf•m)) (lbf•ft)

(107)

(77)

(770)

(550)

(41.0)

(21.5)

(56.0)

(21.5)

(295)

(155)

(405)

(155)

(18.0) (135)

(155)

(66)

(170)

(80)

(295)

(550)

(220)

(26)

(155)

(405)

(1440)

(1030)

(550)

(220)

(550)

(295)

(405)

7-84

MAINTENANCE

Torque Specifications

20 Lower roller mounting bolt

21 Track shoe bolt

23 Track mounting bolt

Descriptions

22 Track guard mounting bolt

Bolt Dia mm

450-3,470H-3 22

450LC-3,

470LCH-3

500LC-3,

520LCH-3

450-3,470H-3 24

450LC-3,

470LCH-3

500LC-3,

520LCH-3

450-3,450LC-3 22

470H-3

470LCH-3

500LC-3,

520LCH-3

450-3,450LC-3,

470H-3,

470LCH-3

500LC-3,

520LCH-3

Coupling and clamp of low pressure piping

Coupling

Clamp

25 Counterweight mounting bolt

26 Shuttle Valve Mounting Bolt

Front pin-retaining bolt

Front pin-retaining nut

NOTE: ★ Hexagonal socket wrench

1/4-28

UNF

Q’ty

392

424

376

Wrench

Size (mm)

N•m

750

950

1400

2000

750

950

1750

13 10.5 to 12.5

★

2200

2400

450

400

(224)

(1.1 to)

(1.3)

(1.0)

(240)

(45.0)

(5.0)

(41.0)

Torque

(kgf•m)) (lbf•ft)

(76.5) (550)

(97.0)

(143)

(204)

(76.5)

(97.0)

(1030)

(1480)

(550)

(700)

(179) (1290)

(1620)

(7.5 to

9.0)

(7.2)

(1730)

(325)

(37)

(295)

7-85

MAINTENANCE

Tightening Torque Chart

Bolt Dia.

Wrench

Size

Hexagon

Wrench

Size

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

M33

M36

750

950

1400

1950

2600

3200

N•m

110

180

270

400

550

(kgf•m)

(3.1)

(6.6)

(11.0)

(18.5)

(27.5)

(41.0)

(56.0)

(76.5)

(97.0)

(143)

(200)

(265)

(325)

M552-07-091

(lbf•ft)

(22)

(48)

(81)

(135)

(200)

(295)

(410)

(550)

(700)

(1030)

(1440)

(1920)

(2360)

550

700

1050

1450

1950

2450

N•m

140

210

300

400

Socket Bolt

(kgf•m)

(2.0)

(5.1)

(9.2)

(14.0)

(21.5)

(30.5)

(41.0)

(56.0)

(71.5)

(107)

(148)

(200)

(250)

M552-07-090

(lbf•ft)

(15.0)

(37)

(66)

(103)

(155)

(220)

(295)

(410)

(520)

(770)

(1070)

(1440)

(1810)

220

280

400

550

750

950

N•m

120

170

WARNING: If fixing bolts for counterweight are loosened, consult your nearest authorized dealer.

IMPORTANT: Make sure bolt and nut threads are clean before installing.

Apply lubricant (e. g. white zinc B solved into spindle oil) to bolts and nuts to stabilize their friction coefficient.

NOTE: Tightening torque required is shown in N•m.

For example, when tightening a bolt or nut with a wrench of 1 m length, turning the end of it with a force of 120 N, the torque produced will be:

1 m ×120 N = 120 N•m

To produce the same torque with a wrench of

0.25 m:

0.25 m × N = 120 N•m

Necessary force will be:

120 N•m ÷ 0.25 m = 480 N

(kgf•m)

(1.0)

(2.0)

(3.6)

(5.6)

(8.2)

(12.0)

(17.0)

(22.5)

(28.5)

(41.0)

(56.0)

(76.5)

(97.0)

M157-07-225

(lbf•ft)

(7.4)

(15.0)

(26.0)

(41)

(59)

(89)

(125)

(162)

(205)

(295)

(410)

(550)

(700)

7-86

MAINTENANCE

1. Retighten engine insulation rubber mounting bolts and nuts.

Mounting Bolts (Front)

Tool: 41 mm

Torque: 1050 N•m (107 kgf•m, 770 lbf•ft)

Mounting Bolts (Rear)

(Engine − Cushion rubber)

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 550 lbf•ft)

(Machine − Cushion rubber)

Tool: 27 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

2. Retighten engine bracket mounting bolts.

Tool: 22 mm

Torque: 210 N•m (21 kgf•m, 155 lbf•ft)

7-87

M1J1-07-046

M1J1-07-022

M1J1-07-040

M1J1-07-043

3. Retighten radiator mounting bolts.

Tool: 30 mm

Torque: 550 N•m (56 kgf•m, 405 lbf•ft)

MAINTENANCE

4. 5. Retighten hydraulic oil and fuel tank mounting bolts.

Tool: 24 mm

Torque: 210 N•m (22 kgf•m, 155 lbf•ft)

6. Retighten ORS fittings for hydraulic hoses and piping.

Tool: 36 mm

Torque: 180 N•m (18 kgf•m, 135 lbf•ft)

Tool: 41 mm

Torque: 210 N•m (22 kgf•m, 155 lbf•ft)

7. Retighten pump device mounting bolts.

Tool: 19 mm

Torque: 90 N•m (9 kgf•m, 66 lbf•ft)

7-88

M1J1-07-021

M111-07-069

M110-07-048

M1J1-07-023

8. Fan pump mounting bolt

Tool: 14 mm Hexagonal Socket Wrench

Torque: 230 N•m (23 kgf•m, 170 lbf•ft)

MAINTENANCE

9. Fan motor mounting bolt

Tool: 19 mm

Torque: 110 N•m (11 kgf•m, 80 lbf•ft)

10. Retighten control valve mounting bolts.

Tool: 30 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

11. Control valve bracket mounting bolt

Tool: 30 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

7-89

M1J1-07-020

M1J1-07-052

M1J1-001

M1JB-07-053

12. Retighten swing device mounting bolts.

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 550 lbf•ft)

MAINTENANCE

13. Retighten swing motor mounting bolts.

Tool: 14 mm Hexagonal Socket Wrench

Torque: 300 N•m (31 kgf•m, 220 lbf•ft)

14. Retighten battery mounting bolts.

Tool: 19 mm

Torque: 35 N•m (3.5 kgf•m, 26 lbf•ft)

15. Retighten cab mounting nut.

Tool: 24 mm

Torque: 210 N•m (22 kgf•m, 155 lbf•ft)

7-90

M1J1-07-014

M1U1-07-026

M1J1-07-001

16. Cab anchor mounting bolt

Tool: 32 mm

Torque: 550 N•m (56 kgf•m, 405 lbf•ft)

MAINTENANCE

17. Retighten swing bearing mounting bolts to upperstructure.

Tool: 46 mm

Torque: 1950 N•m (199 kgf•m, 1440 lbf•ft)

Retighten swing bearing mounting bolts to undercarriage.

Tool: 41 mm

Torque: 1400 N•m (143 kgf•m, 1030 lbf•ft)

M1U1-07-054

M166-07-013

M1J1-07-024

7-91

18. Retighten travel device mounting bolts.

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 550 lbf•ft)

Retighten travel motor mounting bolts.

Tool: 27 mm

Torque: 300 N•m (31 kgf•m, 220 lbf•ft)

MAINTENANCE

Retighten sprocket mounting bolts.

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 550 lbf•ft)

19. Retighten upper roller mounting bolts.

●

ZX450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

Tool: 27 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

●

ZX500LC

-3

, 520LCH

-3

Tool: 30 mm

Torque: 550 N•m (56 kgf•m, 405 lbf•ft)

20. Retighten lower roller mounting bolts.

●

ZX450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 295 lbf•ft)

●

ZX500LC

-3

, 520LCH

-3

Tool: 36 mm

Torque: 950 N•m (97 kgf•m, 700 lbf•ft)

7-92

M1J1-07-026

M107-07-092

M1J1-07-048

M111-07-078

21. Retighten shoe mounting bolts.

●

ZX450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

Tool: 32 mm

Torque: 1400 N•m (143 kgf•m, 1030 lbf•ft)

●

ZX500LC

-3

, 520LCH

-3

Tool: 41 mm

Torque: 2000 N•m (204 kgf•m, 1480 lbf•ft)

MAINTENANCE

22. Retighten track guard mounting bolts.

●

ZX450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

Tool: 32 mm

Torque: 750 N•m (77 kgf•m, 550 lbf•ft)

●

ZX500LC

-3

, 520LCH

-3

Tool: 36 mm

Torque: 950 N•m (97 kgf•m, 700 lbf•ft)

23. Retighten track mounting bolts.

●

ZX450

-3

, 450LC

-3

, 470H

-3

, 470LCH

-3

Tool: 50 mm

Torque: 1750 N•m (178 kgf•m, 1290 lbf•ft)

●

ZX500LC

-3

, 520LCH

-3

Tool: 36 mm

Torque: 2200 N•m (224 kgf•m, 1620 lbf•ft)

24. Retighten coupling and clamp

Coupling

Tool: 13 mm

Torque: 10.5 to 12.5 N•m (1.1 to 1.3 kgf•m, 7.5 to 9.0 lbf•ft)

7-93

M107-07-093

M1J1-07-025

M111-07-079

M1G6-07-008

T-bolt clamp

Tool: 11 mm

Torque: 10 N•m (1 kgf•m, 7.0 lbf•ft)

MAINTENANCE

25. Retighten counterweight mounting bolt.

Tool: 65 mm

Torque: 2400 N•m (245 kgf•m, 1770 lbf•ft)

Tool: 36 mm

Torque: 450 N•m (45 kgf•m, 330 lbf•ft)

26. Retighten shuttle valve mounting bolts.

Tool: 8 mm Hexagonal Socket Wrench

Torque: 50 N•m (5 kgf•m, 37 lbf•ft)

7-94

M162-07-070

M1J1-07-030

M1J1-07-037

M1J1-07-036

27. Retighten front pin-retaining bolts.

Tool: 30 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

MAINTENANCE

M1J1-07-017

M111-07-083

M111-07-084

7-95

Tool: 30 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

MAINTENANCE

M111-07-085

Retighten front pin-retaining nuts.

Tool: 30 mm

Torque: 400 N•m (41 kgf•m, 295 lbf•ft)

M111-07-086

7-96

MAINTENANCE

10 Check O-rings in Bucket Joints --- daily

O-rings (1) are provided on both ends of the bucket joint pins as illustrated to the right, to prevent soil from entering the bucket joints and retain the grease in the bucket joints. Thereby, wear on the bucket joint parts such as the pins and the arm tip can be reduced. Check O-rings (1) for cracks or any damage.

If any, replace the O-ring while referring to the separation type

O-ring installation method described below.(There are two kind of O-ring type.)

M1JB-07-049

Type A (Separation Type O-ring) Installation Method

1. Install the O-ring (1) in the direction as illustrated to the right so that the separation section of the O-ring (1) does not directly come in contact with soil to protect the

O-ring (1) from being damaged quickly by soil or foreign matter.

2. Install the O-ring (1) with care not to make a gap in the separation section of the O-ring.

3. After installing the O-ring (1), cut off the bolt extended from the nut so that the O-ring is not damaged by soil which may come in contact with the bolt.

Cut oﬀ the bolt extended from the nut.

Separation

Section

Type A

Type B (Unit Type O-ring) Installation Method

Slide O-rings (2) out of the way, as shown

O-Ring Shift

M1J1-07-074

7-97

Bucket

Boss

Type B

M104-07-063

11 Retighten Cylinder Head Bolt

--- As required

See your authorized dealer.

MAINTENANCE

12 Inspect and Adjust Valve Clearance

--- every 1 000 hours

See your authorized dealer.

13 Check Fuel Injection Timing

--- As required

See your authorized dealer.

14 Measure Engine Compression Pressure

--- every 1 000 hours

See your authorized dealer.

15 Check Starter and Alternator

--- every 1 000 hours

See your authorized dealer.

16 Check Water Pump

--- every 4 000 hours

See your authorized dealer.

7-98

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT

HYDRAULIC SYSTEM

IIMPORTANT: Hydraulic equipment such as hydraulic pumps, control valves, and relief valves have been adjusted at the factory. Do not attempt to disassemble or turn the adjusting screws, as they are very difficult to readjust. Consult your authorized dealer if any trouble should occur.

• The excavator is equipped with the “O. H. S” (Optimum Hydraulic System) developed by Hitachi.

The “O. H. S” features:

Quick response of the actuators.

Improved precise swinging.

Improved combined operation of each functions.

• The control valve and each circuit are provided with relief valves of sufficient capacity to protect the actuators and other equipment from damage caused by the surge pressure and filter plugging.

• Travel parking brake is automatically released when the travel lever is operated. When the control lever is placed in NEUTRAL, the brake is automatically applied.

• Swing parking brake is automatically released when any control levers except for the travel levers are operated.

When the control lever is placed in NEUTRAL, the brake is automatically applied.

• The excavator is equipped with an accumulator in the hydraulic system in order to operate front attachment for a few seconds after the engine has stopped. The accumulator is charged with high pressure gas: do not attempt to remove or disassemble it, and do not expose the accumulator to flame.

8-1

MAIN CIRCUIT

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT

Bucket

Cylinder

Arm

Cylinder

Boom

Cylinder

Boom

Cylinder

Pilot

Valve

Pilot Shut-oﬀ

Solenoid Valve

Pilot

Control

Valve

Hydraulic Oil Tank

Solenoid

Valve

Center Joint

Swing Motor

Travel (L)

Aux.

Boom II

Arm I

Swing

Travel (R)

Bucket

Boom I

Arm II

Fan

Pump

Relief

Valve

Main

Pump 1

Main

Pump 2

Center Joint

Fan

Motor

Left Travel Motor

Control

Valve

Relief

Valve

Oil

Cooler

Radiator

Accumulator

Air

Cooler

High Pressure Oil

Low Pressure Oil

(Return Line)

Circuit Line

Pilot Line

DrainLine

Right Travel Motor

M1J5-08-001

8-2

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT

8-3

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT

ELECTRICAL CIRCUIT

1. Fusible Link

2. Battery

3. Starter

4. Safety Relay

5. Alternator

6. Glow Plug

7. Washer

8. Work Light (Cab)

9. Work Light (Boom)

10. Work Light (R Fender)

11. Horn

12. Eng. Stop Switch

13. Controller

14. Starter Switch

15. Load Dump Relay

16. Wiper Motor

17. Washer Relay

18. Wiper Relay

19. Room Lamp

20. Cigarette Lighter

21. Radio

22. Wiper

23. Light Relay

24. Horn Relay

25. Horn Switch

26. Compressor

27. Ambient Air Temp. Sensor

28. Blower Motor

29. Air Con. Controller

30. Front Vent Servo Motor

31. Vent Servo Motor

32. Fresh/Circulation Select Servo Motor

33. A/M Servo Motor

34. In-cab Temp. Sensor

35. Frost Sensor

36. Coolant Temp. Sensor

37. Monitor (Indicator)

38. Gate Lock (Pilot shut-off) Relay

39. Gate Lock (Pilot shut-off) Switch

40. Security Relay

41. Starter Cut Relay

42. ECM Main Relay

43. Buzzer

44. Security Horn Relay

45. Security Horn

46. Boom Mode SW

47. Power Digging SW

48. Connector to Dr. ZX

49. Learning SW

50. Gate Lock (Pilot shut-off) Solenoid Valve

51. Glow Relay

52. Auto Lub. Relay

53. Solar Radiation Sensor

54. Blower Main Relay

55. Solenoid Valve Unit

56. Swing Pressure Sensor

57. Fan Pump Solenoid Valve

58. Pump 2 Solenoid Valve

59. Pump 1 Solenoid Valve

60. Overheat SW

61. Pump 2 Pressure Sensor

62. Pump 1 Pressure Sensor

63. Hyd. Temp. Sensor

64. Pressure Sensor (Low)

65. Boom Bottom Pressure Sensor

66. Lubricator Unit

67. Travel Alarm Deactivation SW

68. ICF Controller

69. SW Box

70. Auto Lubricator

71. Coolant Level SW

72. Air Filter Restriction SW

73. Travel Alarm

74. Engine Oil Level SW

75. Engine Oil Pressure Sensor

8-4

ELECTRICAL DIAGRAM

(51)

(2)

(4)

(66)

(1)

(70)

(9)

(10)

(8)

(50)

(40)

(41)

(15)

(39)

(38)

(12)

(11)

(7)

(25)

(24)

(22)

(16)

(17)

(23)

(18)

(23)

(48)

(14)

(20)

(21)

(45)

(44)

(19)

(42)

(52)

(68)

(53)

(37)

(43)

(Normal Open)

(49)

(46)

(67)

(64)

(28)

(54)

(47)

(29)

(31)

(30)

(33)

(32)

(34) (35)

(36)

(69)

(65)

(55) (56)

(63)

(58) (61)

(57) (59) (62)

(72)

(71)

(13)

(26)

(73)

(3)

(27)

(5)

(74)

(60)

(6)

(75)

8-5

HYDRAULIC CIRCUIT AND ELECTLICAL CIRCUIT

8-6

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

Operating Conditions

Muddy Soil, Rainy or

Snowy Weather

Precautions for Maintenance

Before Operation: Check the tightness of plug and all drain cocks.

After Operation: Clean the machine and check for cracks, damaged, loose or missing bolts and nuts. Lubricate all necessary parts without delay.

Near the Ocean Before Operation: Check tightness of plugs and all drain cocks.

Dusty

Atmosphere

After Operation: Thoroughly clean the machine with fresh water to wash off salt. Service electrical equipment often to prevent corrosion.

Air Cleaner: Clean the element regularly at shorter service intervals.

Radiator:

Fuel System:

Clean the oil cooler screen to prevent clogging of the radiator core.

Clean the filter element and strainer regularly at shorter service intervals.

Rocky Ground

Electrical Equipment: Clean them regularly, in particular, the commutator surface of the alternator and starter.

Tracks: Carefully operate while checking for cracks, damage and loose bolts and nuts. Loosen the tracks a little more than usual.

Front Attachment: Standard attachment may be damaged when digging rocky ground. Reinforce the bucket before using it, or use a heavy duty bucket.

Freezing Weather Fuel: Use high quality fuel suitable for low temperature.

Lubricant: Use high quality low viscosity hydraulic oil and engine oil.

Engine Coolant: Be sure to use antifreeze.

Falling Stones

Battery:

Tracks:

Cab:

Fully charge the batteries regularly at shorter service intervals. If not fully charged, electrolyte may freeze.

Keep the track clean. Park the machine on a hard surface to prevent the tracks from freezing to the ground.

Provide a cab guard to protect the machine from falling stones when necessary.

9-1

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS

9-2

STORAGE

STORING THE MACHINE

1. Inspect the machine. Repair worn or damaged parts. Install new parts if necessary.

2. Clean the primary air cleaner element.

3. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with grease.

4. Lubricate all grease points.

5. Park the tracks on long stable blocks.

6. Wash the machine.

7. Remove the batteries and store them in a dry protected place after charging fully. If not removed, disconnect the negative battery cable from the (−) terminal.

8. Add an antirust agent to the coolant. In cold weather, add an antifreeze, or drain the coolant completely. Be sure to attach a “No Water in Radiator” tag on a clearly visible location if the system is drained.

9. Loosen the alternator belt and fan belt.

10. Paint necessary areas to prevent rust.

11. Store the machine in a dry, protected place. If stored outside, cover with a waterproof cover.

12. If the machine is stored for a long time, operate hydraulic functions for travel, swing and digging two to three times for lubrication, at least once a month.

Be sure to check the coolant level and lubrication conditions before operating.

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

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.

4. Start the engine.

Run the engine at half speed for several minutes before full load operation.

5. Cycle all hydraulic functions several times.

6. Carefully check all systems before operating the machine at full load.

NOTE: When the machine has been stored for a long time, be sure to perform the following steps as well:

(a) Check condition of all hoses and connections.

(b) Warm up the engine.

(c) Stop the engine.

(d) Install new fuel filters. Replace the engine oil filter and fill the engine with oil.

IMPORTANT: If the machine has not been used for a long time, oil films on sliding surfaces may have broken down. Cycling hydraulic functions for travel, swing and digging two to three times is necessary to lubricate the sliding surfaces.

10-2

TROUBLESHOOTING

ENGINE

Problem

Engine Cranks But Will Not

Start or Hard to Start

Engine Knocks, Runs Irregularly or Stops

No fuel

Wrong fuel

Cause

Contaminated fuel

Low battery power

Injection pump

Wrong preheat line or glow plugs

Poor electrical connection

Starter motor failure

Wrong engine oil

Air filter plugged

Fuel filter plugged

Engine compression low

Injection nozzles dirty or not working correctly

Fuel shut-off switch

Leaks in fuel system

Air in fuel system

Fuel feed pump plunger up

Feed pump strainer dirty

Fuel pre-filter cock closed

Engine oil level low

Plugged air intake system

Feed pump strainer dirty

Injection pump out of time

Plugged fuel filters

Low coolant temperature

Water, dirt or air in fuel system

Injection nozzles dirty or faulty

Fuel shut-off linkage

Solution

Add fuel.

Bleed air.

Drain tank. Use correct fuel.

Drain tank and add clean fuel.

Charge or install new battery.

See your authorized dealer.

Clean and tighten battery and starter motor connections.

Replace starter.

Drain oil. Use correct oil.

Replace elements.

Remove air from fuel system.

Clean fuel tank strainer.

See your authorized dealer.

Switch on.

Check fuel system connections.

Bleed air.

Push down and tighten knob.

Clean or replace.

Open pre-filter cock.

Add oil.

Clean filter and system.

Clean or replace.

See your authorized dealer.

Install new filters.

Thermostat not working correctly or too

“cool”.

Bleed air from fuel system.

Clean fuel tank outlet screen.

See your authorized dealer.

Adjust or repair linkage.

11-1

TROUBLESHOOTING

ENGINE

Problem

Engine Not Developing Full

Power

Engine Overheats

Cause

Air filters plugged

Fuel line restricted

Contaminated fuel

Fuel filters plugged

Plugged vent in fuel tank cap

Injection nozzles dirty or malfunctioning

Injection pump linkage adjustment

Wrong fuel

Wrong oil

Turbocharger failure

Injection pump out of timing

Exhaust restriction

Engine is too hot or cold

Engine failure

Valve clearance

Intake or exhaust system leakage

Low coolant level

Thermostat

Engine overloaded

Radiator cap faulty

Radiator core or oil cooler core plugged

Radiator screen plugged

Injection pump out of timing

Fan damaged

Air cleaner plugged

Alternator belt loose

Pulley grooves worn

Cooling system passages dirty

Temperature gauge or sending unit

Solution

Replace filter elements.

Repair or replace fuel line.

Drain fuel tank and clean outlet screen.

Refill.

Change filters.

Clean or install new cap.

See your authorized dealer.

Use correct fuel.

Use correct oil.

See your authorized dealer.

Remove muffler and run engine.

See below.

See your authorized dealer.

Check and adjust valves.

See your authorized dealer.

Add coolant.

See your authorized dealer.

Check hydraulic relief valves.

Install new cap.

Clean radiator and oil cooler.

Clean screen.

See your authorized dealer.

Replace fan.

Clean air cleaner.

Tighten or install new belt.

Replace pulleys.

Flush cooling system.

See your authorized dealer.

11-2

TROUBLESHOOTING

ENGINE

Problem

Coolant Temperature Too Low

Thermostat

Low Engine Oil Pressure

Cause

Temperature gauge or sending unit

Engine oil pump or pump drive

Low oil level

Engine oil pressure regulation valve

Plugged oil pump intake screen

Plugged oil filter

Oil leaks

Oil diluted with fuel or coolant

Engine temperature too high

Wrong oil

Engine Uses Too Much Oil

Engine Uses Too Much Fuel

Excessive Black or Gray Exhaust

Smoke

Wrong oil

Oil leaks

Engine temperature too high

Plugged air cleaner

Internal engine component wear

Plugged or dirty air intake system

Wrong fuel

Fuel injection nozzles

Injection pump out of time

Wrong fuel

Plugged or dirty air intake or exhaust system

Injection pump out of timing

Injection nozzles dirty or faulty

Basic engine failures

Solution

See your authorized dealer.

Add oil.

See your authorized dealer.

Install a new oil filter.

Check for leaks.

See your authorized dealer.

Check cooling system.

Drain oil. Use correct oil.

Check engine oil drain plug.

Check cooling system.

Clean element or install new element.

See your authorized dealer.

Clean air intake system.

Use correct fuel.

See your authorized dealer.

Drain tank. Use correct fuel.

Clean air intake and exhaust system.

See your authorized dealer.

11-3

TROUBLESHOOTING

ENGINE

Problem

Exhaust Gas is White

Turbocharger Excessively Noisy or Vibrates

Oil Dripping from Turbocharger Adapter

Excessive Drag in Turbo-charger Rotating Members

Wrong fuel

Cold engine

Cause

Thermostat faulty or too “cool”

Injection pump out of time

Coolant leakage into engine cylinder

Injection nozzles failure

Bearings not lubricated

Worn bearings

Air leak in engine, intake or exhaust manifold

Improper clearance between turbine wheel and turbine housing

Broken blades on turbine

Solution

Drain tank. Use correct fuel.

Run engine until warm.

See your authorized dealer.

Insufficient oil pressure.

Check for restricted turbocharger oil line.

See your authorized dealer.

Inspect, repair.

See your authorized dealer.

Damaged or worn bearings and/or worn seals

Excessive crankcase pressure

Remove exhaust elbow and air inlet hose and inspect.

See your authorized dealer.

Inspect and clean air cleaner.

Check for proper engine service intervals or dirt enter into engine.

Check vent tube to ensure tube is not plugged.

Clean.

Remove line.

Inspect, clean.

Turbocharger oil return line carbon build up where line passes exhaust manifold

Carbon build-up behind turbine wheel caused by combustion deposits

Dirt build-up behind compressor wheel caused by air intake leaks

Bearing seizure or dirty or worn bearings, caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication

Inspect, clean.

See your authorized dealer.

11-4

TROUBLESHOOTING

ELECTRICAL SYSTEM

Problem

Nothing Works

Nothing Works (Except clock)

Batteries Undercharged

Starting Motor Will Not Turn

Starter Solenoid Chatters

Starter Motor Turns but Will

Not Crank Engine

Engine Cranks Slowly

Cause

Battery

Battery relay

Loose or corroded connections

Alternator belt loose

Alternator not charging

Fuse

Key switch failure

Battery undercharged or dead

Battery cables making poor connections

Fusible link

Key switch

Start relay

Starter solenoid

Starter

Starter pinion jammed in flywheel gear

Major engine failure

The pilot control shut-off lever is dowm

Position

Poor connections at batteries or starter

Low battery charge

Starter solenoid “hold-in” windings open

Starter pinion gear not engaging flywheel ring gear

Pinion shift mechanism jammed or malfunctioning

Pinion gear teeth broken

Flywheel gear teeth broken

The engine stop switch is activated

Battery cables damaged or broken internally

Battery or starter cable connections loose or corroded

Solution

Recharge or replace.

Replace relay.

Clean and tighten or replace batteries.

Tighten or install new belt.

See your authorized dealer.

Replace fuse.

Replace key switch.

Recharge or replace battery.

Clean connections.

Replace fusible link.

See your authorized dealer.

Repair or replace start motor.

Repair or replace starter.

See your authorized dealer.

Pull the pilot control shut-off lever up to the LOCK position

Clean connections.

Recharge or replace batteries.

See your authorized dealer.

Turn the engine stop switch off

Inspect and replace cables.

Clean and tighten connections.

11-5

TROUBLESHOOTING

ELECTRICAL SYSTEM

Problem

Engine Cranks Slowly

Starter Motor Continues to Run

After Engine Starts

Charging Indicator Light On-

Engine Running

Noisy Alternator

No Monitor Panel Indicators

Work

Individual Light in Monitor

Panel is Not Working

Cause

Battery discharged or will not hold a charge

Starter “dragging”

Low battery voltage

Start relay stuck

Starter solenoid stuck

Starter not disengaging

Key switch

Loose or glazed alternator belt

Engine rpm low

Excessive electrical load from added accessories

Loose or corroded electrical connections on battery, ground strap, starter, or alternator

Battery voltage low

Alternator or regulator

Indicator circuit

Worn drive belt

Worn pulleys

Pulley misaligned

Alternator bearing

Fuse

Wiring harness

Bulb

Fuse

Wiring harness

Solution

Replace battery.

See your authorized dealer.

Recharge or replace battery.

See your authorized dealer.

Check belt.

Replace if glazed, tighten if loose.

Adjust rpm to specification.

Remove accessories or install higher output alternator.

Inspect, clean, or tighten electrical connections.

Change or replace battery.

See your authorized dealer.

Replace belt.

Replace pulleys and belt.

Adjust alternator mount.

Loosen alternator belts.

Turn pulley by hand.

If any roughness is felt, repair alternator.

Replace fuse.

See your authorized dealer.

Replace bulb.

Replace fuse.

See your authorized dealer.

11-6

TROUBLESHOOTING

ELECTRICAL SYSTEM

Problem

No Indicators in Gauge Panel

Operate

Indicator Light in Gauge Panel is Inoperative

Coolant Temperature Gauge

Does Not Work

Cause

Circuit board

Wiring harness

Fuse

Bulb

Fuse

Sender

Wiring harness failure

Fuse

Gauge

Gauge sender

Indicator Lights Do Not Operate Auto-idle

Fuel Gauge Does Not Work

Wiring harness

Fuse

Bulb

Auto-idle switch

Fuse

Gauge

Wiring harness

Solution

See your authorized dealer.

Replace fuse.

Replace bulb.

Replace fuse.

Do sender check.

See your authorized dealer.

Replace fuse.

See your authorized dealer.

Do coolant temperature gauge sender check.

See your authorized dealer.

Replace fuse.

Replace bulb.

See your authorized dealer.

Replace fuse.

See your authorized dealer.

11-7

Problem

Work Mode Selector

Does Not Work

Fast/Slow Travel Speed

Does Not Function

Auto-Idle Does Not Work

TROUBLESHOOTING

ELECTRICAL SYSTEM

Cause

Mode switches

Electrical connector

Wire harness (between MC and monitor)

Main controller (MC)

Solenoid valve unit

Travel mode switches

Pilot pressure switch (Travel)

Pump delivery pressure sensor wire harness

Main controller (MC)

Solenoid valve unit

Damaged travel motor

Fuse

Switch panel

Electrical connector

Wire harness

EC motor

Pressure switches (Travel, Front)

Main controller

Solution

See your authorized dealer.

Replace fuse.

See your authorized dealer.

11-8

TROUBLESHOOTING

CONTROL LEVERS

Problem

Moves Hard

Worn out pusher

Cause

Pilot valve

Does Nothing

Worn out pusher

Pilot valve

Does Not Return to Neutral

Pilot valve

Too Much Play

Worn out pivot joint

Lever is Not Vertical In Neutral

Pilot valve

Solution

See your authorized dealer.

Problem

Hydraulic Functions are Slow

Hydraulic Oil Overheats

HYDRAULIC SYSTEM

Cause

Low oil level

Cold oil

Wrong oil

Engine speed too low

Pilot circuit

Worn pump

Restricted pump suction line

Wrong oil

Air leak in pump suction line

Oil lines restricted

Low oil level

Plugged filters

Worn pump

Plugged radiator or oil cooler

Oil cooler bypass

Solution

Fill reservoir to full mark.

Push hydraulic warm up switch.

Drain tank. Use correct oil.

Increase speed or see your authorized dealer.

See your authorized dealer.

Use correct oil.

See your authorized dealer.

Fill reservoir to full mark.

Install new filters.

See your authorized dealer.

Clean and straighten fins.

See your authorized dealer.

11-9

TROUBLESHOOTING

HYDRAULIC SYSTEM

Oil Foams

Problem

Hydraulic Oil Overheats

Low or No Oil Pressure

No Hydraulic Functions

(Noise from pumps)

Hydraulic Cylinders Operate but Cannot Lift Load

Cause

Relief valve

Contaminated oil

Travel motors

Improperly adjusted hydraulic components

Air leak in line from reservoir to pump

Solution

See your authorized dealer.

Drain oil and refill.

See your authorized dealer.

Kinks or dents in oil lines

Wrong oil

Water in oil

High or low oil level

Wrong oil

Improperly adjusted hydraulic components

No oil in system

Worn cylinder packings

Relief valve

Hydraulic pump

Lack of hydraulic oil

Damaged suction line or hose

Clogged suction filter

Hydraulic pump worn

Main relief valve pressure low

Hydraulic oil level low

Suction screen plugged

Pump suction line leaking

Repair leak or see your authorized dealer.

Check lines.

Use correct oil.

Change oil.

Correct level.

Use correct oil.

See your authorized dealer.

Fill with correct oil.

See your authorized dealer.

Add oil.

See your authorized dealer.

Clean.

See your authorized dealer.

Add oil.

Clean strainer and system.

Inspect suction line.

11-10

TROUBLESHOOTING

HYDRAULIC SYSTEM

One Control Lever Does Not

Work

Problem

One Cylinder Does Not Work

One Cylinder Does Not Work or

Has Little Power

Cause

Relief valve pressure low

Tube or hose damaged

Hydraulic fittings loose

Damaged O-rings in fittings

Hydraulic Pump

Pilot valve

Pilot lines

Control valve spool damaged or contaminated with dirt

Hydraulic lines damaged

Fittings loose

O-ring in fitting damaged

Pilot valve

Pilot lines

Piston seals leaking

Cylinder rod damaged

Pilot lines

Pilot valve

Failed wiring harness

Center joint failure

Both Travel Motors Do Not

Work

Travel Motor Does Not Work

Travel is Not Smooth

Travel motor

Parking brake not releasing

Pilot valve

Pilot lines

Track adjustment

Track idler or rollers damaged

Track frame bent

Solution

See your authorized dealer.

Repair or replace.

Tighten.

Install new O-ring.

See your authorized dealer.

Repair or replace.

See your authorized dealer.

Repair or replace.

Tighten.

Install new O-ring.

See your authorized dealer.

Repair or replace.

See your authorized dealer.

Repair or replace.

See your authorized dealer.

Repair or replace.

Adjust tension.

See your authorized dealer.

11-11

TROUBLESHOOTING

HYDRAULIC SYSTEM

Problem

Travel is Not Smooth

Swing Does Not Work

Swing is Not Smooth

Engine Stops When Travel or/ and Control Lever Moved

Cause

Rocks or mud “jammed” in track frame

Travel brake not releasing

Swing brake release valve

Swing motor

Pilot valve

Swing gear

Swing bearing

Lack of grease

Failure of connector contact

Failed wiring harness

Failed Main controller

Solution

Remove and repair.

See your authorized dealer.

Apply grease.

Repair or replace.

See your authorized dealer.

11-12

SPECIFICATIONS

SPECIFICATIONS (BACKHOE)

ZAXIS450

-3

, ZAXIS450LC

-3

, ZAXIS500LC

-3

M1J1-12-001

Model

Type of Front-End Attachment

Bucket Capacity (Heaped)

ZAXIS450

-3

ZAXIS450LC

-3

3.4 m (11 ft 2 in) Arm

ZAXIS500LC

-3

Operating Weight

Base Machine Weight

Engine

PCSA 1.89 m

(2.47 yd

CECE 1.7 m

45700 kg (100800 lb)

35600 kg (78500 lb)

PCSA 2.07 m

(2.71 yd

CECE 1.8 m

46600 kg (102700 lb)

36500 kg (80500 lb)

260 kW/1800 min

-1

(353 PS/1800 rpm)

PCSA 2.07 m

(2.71 yd

CECE 1.8 m

49500kg (109100 lb)

39400kg (86900 lb)

A: Overall Width

(Excluding Back Mirrors)

B: Cab Height

C: Rear End Swing Radius

D: Minimum Ground Clearance

E: Counterweight Clearance

3740 mm (12 ft 3 in)

3330 mm (10 ft 11 in)

3520 mm (11 ft 7 in)

*760 mm (30 in)

3740 mm (12 ft 3 in)

3330 mm (10 ft 11 in)

3520 mm (11 ft 7 in)

*760 mm (30 in)

3860mm (12 ft 8 in)

3410 mm (11 ft 2 in)

3520 mm (11 ft 7 in)

*840 mm (33 in)

F: Engine Cover Height

G: Overall Width of Upper structure

H: Undercarriage Length

I: Undercarriage Width

* 1400 mm (4 ft 7 in)

3080mm (10 ft 1 in)

3530 mm (11 ft 7 in)

5040 mm (16 ft 6 in)

3490 mm (11 ft 5 in)

2990 mm (9 ft 10 in)

(Extended/Retracted)

* 1400 mm (4 ft 7 in)

3080mm (10 ft 1 in)

3530 mm (11 ft 7 in)

5470 mm (17 ft 11 in)

3490 mm (11 ft 5 in)

2990 mm (9 ft 10 in)

(Extended/Retracted)

*1470 mm (4 ft 10 in)

3160 mm(10 ft 4 in)

3530 mm (11 ft 7 in)

5330 mm (17 ft 6 in)

3520 mm (11 ft 7 in)

3070 mm (10 ft 1 in)

J: Sprocket Center to Idler

Center

K: Track Shoe Width

L: Overall Height

Ground Pressure

Swing Speed

Travel Speed (fast/slow)

Grade ability

4040 mm (13 ft 3 in) 4470 mm (14 ft 8 in) 4250mm (13 ft 11 in)

600 mm (24 in) (Grouser shoe)

3460 mm (11 ft 4 in)

85 kPa (0.87 kgf/cm

3460 mm (11 ft 4 in)

, 12 psi) 79 kPa (0.81 kgf/cm

9.0 min

-1

(rpm)

3540 mm (11 ft 7 in)

, 12 psi) 87 kPa (0.89 kgf/cm

, 13 psi)

5.5/3.4 km/h (3.4/2.1 mph) 4.0/2.9km/h (2.5/1.8 mph)

35° (tanθ = 0.70)

NOTE: * The dimensions do not include the height of the shoe lug.

12-1

WORKING RANGES (BACKHOE)

ZAXIS450

-3

, ZAXIS450LC

-3

SPECIFICATIONS

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 Backhoe Backhoe Backhoe Backhoe

ZX450

-3

ZX450LC

-3

ZX450

-3

ZX450LC

-3

ZX450

-3

ZX450LC

-3

ZX450

-3

ZX450LC

-3

ZX450

-3

ZX450LC

-3

Item

A: Maximum mm

Digging Reach (ft•n)

B: Maximum mm

Digging Depth (ft•n)

C: Maximum mm

Cutting Height (ft•n)

D: Maximum mm

Dumping Height (ft•n)

E: Transport

Height mm

(ft•n)

F: Overall mm

Transport Length (ft•n)

G: Minimum mm

Swing Radius (ft•n)

11400

(37’5”)

7280

(23’11”)

10250

(33’8”)

7030

(23’1”)

*3600

(11’10”)

*12000

(39’4”)

5020

(16’6”)

11400

(37’5”)

7280

(23’11”)

10250

(33’8”)

7030

(23’1”)

*3600

(11’10”)

*12000

(39’4”)

5020

(16’6”)

12060

(39’7”)

7770

(25’6”)

11060

(36’3”)

7650

(25’1”)

*3480

(11’5”)

*11910

(39’1”)

4840

(15’11”)

12060

(39’7”)

7770

(25’6”)

11060

(36’3”)

7650

(25’1”)

*3480

(11’5”)

*11910

(39’1”)

4840

(15’11”)

12490

(40’12”)

8270

(27’7”)

11160

(36’7”)

7770

(25’3”)

*3500

(11’6”)

*11910

(39’1”)

4810

(15’9”)

NOTE: * The dimensions do not include the height of the shoe lug.

12490

(40’12”)

8270

(27’7”)

11160

(36’7”)

7770

(25’3”)

*3500

(11’6”)

*11910

(39’1”)

4810

(15’9”)

13340

(43’9”)

9110

(29’11”)

11730

(38’6”)

8670

(28’5”)

*4550

(14’11”)

*11900

(39’1”)

4850

(15’11”)

13340

(43’9”)

9110

(29’11”)

11730

(38’6”)

8670

(28’5”)

*4550

(14’11”)

*11900

(39’1”)

4850

(15’11”)

14510

(47’7”)

10230

(33’7”)

12240

(40’2”)

9220

(30’3”)

*4430

(14’6”)

*13130

(43’1”)

5870

(19’3”)

14510

(47’7”)

10230

(33’7”)

12240

(40’2”)

9220

(30’3”)

*4430

(14’6”)

*13130

(43’1”)

5870

(19’3”)

12-2

ZAXIS500LC

-3

SPECIFICATIONS

M1J1-12-003

Item

SHOE TYPES AND APPLICATIONS

ZAXIS450

-3

Shoe Width mm (in)

Application

Operating Weight kg

(lb)

Base Machine Weight kg

(lb)

Cab Height mm

(ft•in)

Minimum Ground mm

Clearance (ft•in)

Undercarriage

Length mm

(ft•in)

Undercarriage Width mm

(ft•in)

Ground Pressure

600 mm (24")

Grouser Shoe

For Ordinary Ground (Standard)

45700

(100800)

35600

(78500)

3330

(10’11”)

*720

(28”)

5040

(16’6”)

3490/2990

(11’5”/9’10”)

(Extended/Retracted)

85 kPa

(0.87 kgf/cm

, 12 psi)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

46400

(102300)

36300

(80000)

3330

(10’11”)

*720

(28”)

5040

(16’6”)

3640/3140

(11’11”/10’4”)

69 kPa

(0.70 kgf/cm

, 10 psi)

ZAXIS450LC

-3

Shoe Width mm (in)

Application

Operating Weight kg

(lb)

Base Machine Weight kg

(lb)

Cab Height mm

(ft•in)

Minimum Ground mm

Clearance (ft•in)

600 mm (24")

Grouser Shoe

For Ordinary Ground

(Standard)

46600

(102700)

36500

(80500)

3330

(10’11”)

*720

(28”)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

47400

(104500)

37300

(82200)

3330

(10’11”)

*720

(28”)

900 mm (35")

Grouser Shoe

For Weak Footing (Option)

48100

(10600)

37900

(83600)

3330

(10’11”)

*720

(28”)

Undercarriage

Length

Undercarriage Width mm

(ft•in)

(Extended/Retracted)

Ground Pressure mm

(ft•in)

5470

(17’11”)

3490/2990

(11’5”/9’10”)

5470

(17’11”)

3640/3140

(11’11”/10’4”)

5470

(17’11”)

3790/3290

(12’5”/10’10”)

90 kPa

(0.92 kgf/cm

, 13 psi)

64 kPa

(0.65 kgf/cm

, 9 psi)

54 kPa

(0.55 kgf/cm

, 8 psi)

NOTE: • The specifications for the front-end attachment are for 3.4 m (11 ft 2 in) arm with PCSA 1.89 m

(2.47 yd

ZAXIS450

-3

or PCSA 2.07 m

(2.71 yd

) for ZAXIS450LC

-3

• 750 mm (30 in) and 900 mm (35 in) grouser shoe should not be used on gravel or rocky ground.

• * The dimensions do not include the height of the shoe lug.

) bucket for

12-4

SPECIFICATIONS

ZAXIS500LC

-3

Shoe Width mm (in)

Application

Operating Weight

Cab Height

Clearance

Undercarriage

Length

Undercarriage

Width

Ground Pressure kg

(lb)

Base Machine Weight kg

(lb) mm

(ft•in)

Minimum Ground mm

(ft•in) mm

(ft•in)

600 mm (24")

Grouser Shoe

For Ordinary Ground

(Standard)

49500

(109100)

39400

(86900)

3410

(11’2”)

*840

(33”)

5330

(17’6”)

3520/3020

(11’7”/9’11”)

(Extended/Retracted)

87 kPa

(0.89 kgf/cm

, 13 psi)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

50300

(110900)

40200

(88600)

3410

(11’2”)

*840

(33”)

5330

(17’6”)

3670/3170

(12’1”/10’5”)

(Extended/Retracted)

89 kPa

(0.91 kgf/cm

, 13 psi)

900 mm (35")

Grouser Shoe

For Weak Footing (Option)

51200

(112900)

40900

(90200)

3410

(11’2”)

*840

(33”)

5330

(17’6”)

3820/3320

(12’6”/10’11”)

(Extended/Retracted)

62 kPa

(0.63 kgf/cm

, 9 psi)

NOTE: • The specifications for the front-end attachment are for 3.4 m (11 ft 2 in) arm with PCSA 2.07 m

(2.71 yd

) bucket for

ZAXIS500LC

-3

• 750 mm (30 in) and 900 mm (35 in) grouser shoe should not be used on gravel or rocky ground.

• * The dimensions do not include the height of the shoe lug.

12-5

SPECIFICATIONS

BUCKET TYPES AND APPLICATIONS (BACKHOE)

ZAXIS450

-3

, ZAXIS450LC

-3

Bucket Capacity m

(yd

)

Bucket

PCSA

(Heaped)

CECE

(Heaped)

Bucket

Width mm (in)

(With side cutter)

2.9 m

(9'6")

Arm

ZX450-3

7.0 m (23’0”) Boom

3.4 m

(11’2”)

Arm

3.9 m

(12’10”)

Arm

Hoe

Bucket

1.13

(1.48)

1.36

(1.78)

1.60

(2.09)

1.89

(2.47)

2.07

(2.71)

2.28

(2.98)

1.0

1.2

1.4

1.7

1.8

2.0

1210

(48”)

1410

(56”)

1360

(54”)

1540

(61”)

1630

(64”)

1660

(65”)

4.9 m

(46’1”)

Arm

Front-End Attachment

8.2 m

(26’ 10”)

Boom

4.9 m

(46’1”)

Arm

2.9 m

(9'6")

Arm

ZX450LC-3

7.0 m (23’ 0”) Boom

3.4 m

(11’2”)

Arm

3.9 m

(12’10”)

Arm

4.9 m

(46’1”)

Arm

8.2 m

(26’ 10”)

Boom

4.9 m

(46’1”)

Arm

ZAXIS500LC

-3

Bucket Capacity m

(yd

)

Front-End Attachment

Bucket

CECE

(Heaped)

Bucket

Width mm (in)

(With side cutter)

7.0 m (23’0”) Boom

PCSA

(Heaped)

2.9 m

(9'6")

Arm

3.4 m

(11’2”)

Arm

3.9 m

(12’10”)

Arm

4.9 m

(46’1”)

Arm

Hoe

Bucket

1.13

(1.48)

1.36

(1.78)

1.60

(2.09)

1.89

(2.47)

2.07

(2.71)

2.28

(2.98)

1.0

1.2

1.4

1.7

1.8

2.0

1210

(48”)

1410

(56”)

1360

(54”)

1540

(61”)

1630

(64”)

1660

(65”)

NOTE: • Symbols in the above table have the following meanings.

: General excavating

: Light duty excavating

: Not applicable (not warrantable)

: Impossible to install

8.2 m

(26’ 10”)

Boom

4.9 m

(46’1”)

Arm

• Hoe bucket is applicable to the following types of work.

General excavating:

For digging and loading operation of sand, gravel, clay, ordinary earth and so on.

Light duty excavating:

For digging and loading operation of dry, loosened earth, sand, mud and so on.

Their bulk density shall be less than 1.60 t/m

(2700 lbf/yd

) as a standard.

12-6

SPECIFICATIONS

SPECIFICATIONS (BACKHOE)

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

M1J1-12-003

Model

Type of Front-End Attachment

Bucket Capacity (Heaped)

Operating Weight

Base Machine Weight

Engine

A: Overall Width

(Excluding Back Mirrors)

B: Cab Height

C: Rear End Swing Radius

D: Minimum Ground Clearance

E: Counterweight Clearance

F: Engine Cover Height

G: Overall Width of Upper structure

H: Undercarriage Length

I: Undercarriage Width

ZAXIS470H

-3

47100 kg (103800 lb)

36100 kg (79600 lb)

3770 mm (12 ft 4 in)

3450 mm (11 ft 4 in)

3520 mm (11 ft 7 in)

*760 mm (30 in)

* 1400 mm (4 ft 7 in)

3080mm (10 ft 1 in)

3530 mm (11 ft 7 in)

ZAXIS470LCH

3.4 m (11 ft 2 in) HD Arm

PCSA 1.89 m

(2.47 yd

260 kW/1800 min

-1

-3

), CECE 1.7 m

48100 kg (106000 lb)

37100 kg (81800 lb)

(353 PS/1800 rpm)

3770 mm (12 ft 4 in)

3450 mm (11 ft 4 in)

3520 mm (11 ft 7 in)

*760 mm (30 in)

* 1400 mm (4 ft 7 in)

3080mm (10 ft 1 in)

3530 mm (11 ft 7 in)

ZAXIS520LCH

-3

51700kg (114000 lb)

40600kg (89500 lb)

3860mm (12 ft 8 in)

3520 mm (11 ft 7 in)

*840 mm (33 in)

*1470 mm (4 ft 10 in)

3160 mm(10 ft 4 in)

3530 mm (11 ft 7 in)

5040 mm (16 ft 6 in)

3490 mm (11 ft 5 in)

2990 mm (9 ft 10 in)

(Extended/Retracted)

5470 mm (17 ft 11 in)

3490 mm (11 ft 5 in)

2990 mm (9 ft 10 in)

(Extended/Retracted)

5330 mm (17 ft 6 in)

3520 mm (11 ft 7 in)

3070 mm (10 ft 1 in)

J: Sprocket Center to Idler

Center

K: Track Shoe Width

L: Overall Height

Ground Pressure

Swing Speed

Travel Speed (fast/slow)

Grade ability

4040 mm (13 ft 3 in) 4470 mm (14 ft 8 in) 4250mm (13 ft 11 in)

600 mm (24 in) (Grouser shoe)

3460 mm (11 ft 4 in)

88 kPa (0.89 kgf/cm

3460 mm (11 ft 4 in)

, 13 psi) 82 kPa (0.83 kgf/cm

3540 mm (11 ft 7 in)

, 12 psi) 91 kPa (0.93 kgf/cm

, 13 psi)

9.0 min

-1

(rpm)

5.5/3.4 km/h (3.4/2.1 mph) 4.0/2.9km/h (2.5/1.8 mph)

35° (tanθ = 0.70)

NOTE: * The dimensions do not include the height of the shoe lug.

12-7

SPECIFICATIONS

WORKING RANGES (BACKHOE)

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

SHOE TYPES AND APPLICATIONS

ZAXIS470H

-3

Shoe Width mm (in)

Application

Operating Weight kg

(lb)

Base Machine Weight kg

(lb)

Cab Height mm

(ft•in)

Minimum Ground mm

Clearance (ft•in)

Undercarriage

Length mm

(ft•in)

Undercarriage Width mm

(ft•in)

(Extended/Retracted)

Ground Pressure

SPECIFICATIONS

600 mm (24")

Grouser Shoe

For Ordinary Ground (Standard)

47100

(103800)

36100

(79600)

3450

(11’4”)

*760

(30”)

5040

(16’6”)

3490/2990

(11’5”/9’10”)

88 kPa

(0.89 kgf/cm

, 13 psi)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

47900

(105600)

36800

(81100)

3450

(11’4”)

*760

(30”)

5040

(16’6”)

3640/3140

(11’11”/10’4”)

71 kPa

(0.72 kgf/cm

, 10 psi)

ZAXIS470LCH

-3

Shoe Width mm (in)

Application

Operating Weight kg

(lb)

Base Machine Weight kg

(lb)

Cab Height mm

(ft•in)

Minimum Ground mm

Clearance (ft•in)

Undercarriage

Length mm

(ft•in)

Undercarriage Width mm

(ft•in)

(Extended/Retracted)

600 mm (24")

Grouser Shoe

For Ordinary Ground (Standard)

48100

(106000)

37100

(81800)

3450

(11’4”)

*760

(30”)

5040

(16’6”)

3490/2990

(11’5”/9’10”)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

48900

(107800)

37900

(83550)

3450

(11’4”)

*760

(30”)

5040

(16’6”)

3640/3140

(11’11”/10’4”)

Ground Pressure 82 kPa

(0.83 kgf/cm

, 12 psi)

66 kPa

(0.67 kgf/cm

, 10 psi)

NOTE: • The specifications for the front-end attachment are for 3.4 m (11 ft 2 in) arm with PCSA 1.89 m

• * The dimensions do not include the height of the shoe lug.

(2.47 yd

) bucket.

12-9

SPECIFICATIONS

ZAXIS520LCH

-3

Shoe Width mm (in)

Application

Operating Weight kg

(lb)

Base Machine Weight kg

(lb)

Cab Height mm

(ft•in)

Minimum Ground mm

Clearance (ft•in)

600 mm (24")

Grouser Shoe

For Ordinary Ground (Standard)

51700

(114000)

40600

(89500)

3520

(11’7”)

*840

(33”)

750 mm (30")

Grouser Shoe

For Weak Footing (Option)

51800

(114200)

40800

(89550)

3520

(11’7”)

*840

(33”)

Undercarriage

Length

Undercarriage Width mm

(ft•in)

(Extended/Retracted)

Ground Pressure mm

(ft•in)

5330

(17’6”)

3520/3020

(11’7”/9’11”)

5330

(17’6”)

3760/3170

(12’1”/10’5”)

91 kPa

(0.93 kgf/cm

, 13 psi)

73 kPa

(0.75 kgf/cm

, 11 psi)

NOTE: • The specifications for the front-end attachment are for 3.4 m (11 ft 2 in) arm with PCSA 1.89 m

• * The dimensions do not include the height of the shoe lug.

(2.47 yd

) bucket.

12-10

SPECIFICATIONS

BUCKET TYPES AND APPLICATIONS (BACKHOE)

ZAXIS470H

-3

, ZAXIS470LCH

-3

, ZAXIS520LCH

-3

Bucket Capacity m

(yd

)

Front-End Attachment

Bucket

PCSA

(Heaped)

CECE

(Heaped)

Bucket Width mm (in)

(With side cutter)

ZX470H

-3

3.4 m

(11’2”) H Arm

ZX470LCH

-3

3.4 m

(11’2”) H Arm

Rock Bucket

Ripper Bucket

1.89 (2.47)

1.36 (1.78)

1.6

1.2

1480 (58”)

1170 (46”)

(Without side cutter)

— One Point Ripper — —

NOTE: • Symbols in the above table have the following meanings.

: Rock digging

For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.

ZX520LCH

-3

3.4 m

(11’2”) H Arm

12-11

SPECIFICATIONS

LIFTING CAPACITIES

NOTE: 1. Lifting capacity of the ZX series does not exceed

75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. (ISO

10567)

2. * Indicates load limited by hydraulic capacity.

M1G6-13-013

A: Load radius

B: Load point height

METRIC MEASURE

ZX470LCH

-3

Boom (H) 7.0 m , Arm (H) 3.4 m, Without Bucket Shoes 600 mm

B: Load point height m

2.0 m 3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m 9.0 m 10.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

10.1 10.2 *

12.2 12.3 * 9.9 11.5 * 8.2 10.9 *

7.8 * 7.8 * 8.4

7.5 7.6 * 9.4

25.2 * 25.2 * 19.0 19.3 * 14.5 16.1 * 11.5 14.0 * 9.5 12.6 * 7.9 11.7 * 6.7 7.9 * 6.7 7.8 * 10.0

17.3 23.0 * 13.4 18.6 * 10.8 15.8 * 9.0 13.8 * 7.6 12.1 6.5 10.3 6.3 8.4 * 10.2

(GROUND)

12.8 * 12.8 * 16.7 23.9 * 12.8 19.6 * 10.4 16.6 * 8.6 14.1 7.4 11.9

-2.0

13.1 * 13.1 * 16.2 * 16.2 * 23.0 * 23.0 * 16.6 22.5 * 12.7 19.0 * 10.2 16.2 * 8.5 14.0 7.3 11.8

-4.0

26.0 * 26.0 * 22.2 * 22.2 * 16.9 19.0 * 12.9 16.2 * 10.4 13.8 *

-5.0

18.6 * 18.6 * 16.1 * 16.1 * 13.2 13.6 * 10.7 10.9 *

6.5 9.5 * 9.9

7.1 11.5 9.2

8.8 11.3 * 7.9

10.7 10.8 * 7.0

ZX520LCH

-3

Boom (H) 7.0 m , Arm (H) 3.4 m, Without Bucket Shoes 600 mm

B: Load point height m

2.0 m 3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m 9.0 m 10.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

(GROUND)

10.4 * 10.4 *

12.3 * 12.3 * 11.0 11.6 * 9.1 11.1 * 7.6 * 7.6 * 9.5

24.7 * 24.7 * 19.4 * 19.4 * 16.1 16.2 * 12.8 14.1 * 10.5 12.7 * 8.8 11.7 * 7.5 8.0 * 7.5 7.8 * 10.0

19.4 23.1 * 15.0 18.7 * 12.1 15.8 * 10.1 13.8 * 8.5 12.3 7.3 10.4 * 7.1 8.4 * 10.1

13.1 * 13.1 * 18.8 23.8 * 14.4 19.7 * 11.7 16.6 * 9.7 14.3 8.3 12.1

-2.0

13.5 * 13.5 * 16.7 * 16.7 * 23.4 * 23.4 * 18.8 22.4 * 14.3 18.9 * 11.5 16.1 * 9.6 13.9 * 8.3 11.9 *

-4.0

25.7 * 25.7 * 22.0 * 22.0 * 18.8 * 18.8 * 14.5 16.1 * 11.7 13.6 *

-5.0

18.3 * 18.3 * 15.8 * 15.8 * 13.3 * 13.3 *

7.8 * 7.8 * 8.4

7.3 9.5 * 9.9

8.1 11.5 * 9.2

10.0 11.3 * 7.9

10.8 * 10.8 * 6.9

12-12

SPECIFICATIONS

LIFTING CAPACITIES

NOTE: 1. Lifting capacity of the ZX series does not exceed

75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. (ISO

10567)

2. * Indicates load limited by hydraulic capacity.

M1G6-13-013

A: Load radius

B: Load point height

METRIC MEASURE

ZX470LCH

-3

Boom (BE) 6.3 m , Arm (BE) 2.9 m, Without Bucket Shoes 600 mm

B: Load point height m

3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

(GROUND)

24.0

25.7 * 17.0

24.0 * 13.1

19.9 * 10.6

16.9 * 8.8

-2.0

28.4 * 28.4 * 24.2

26.4 * 16.9

22.1 * 13.0

18.5 * 10.5

15.6 *

-4.0

19.6 * 19.6 * 16.6 * 16.6 * 13.4

13.5 *

14.3

8.0

9.1

10.1

8.6

13.4 * 7.8

12.5 * 12.5 * 6.3

-6.0

-8.0

13.6 * 13.6 * 8.2 * 8.2 * 6.8

14.4 * 14.4 * 12.2

13.5 * 9.0 * 9.0 * 7.8 * 7.8 * 8.1

25.0 * 25.0 * 19.3

19.7 * 14.6

16.7 * 11.6

14.8 * 9.5

13.6 * 8.0 * 8.0 * 8.7

17.7

23.2 * 13.6

19.0 * 11.0

16.3 * 9.1

14.4 * 7.8

8.7 * 8.9

ZX520LCH

-3

Boom (BE) 6.3 m , Arm (BE) 2.9 m, Without Bucket Shoes 600 mm

B: Load point height m

3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

(GROUND)

26.1 * 26.1 * 19.1

24.0 * 14.7

19.9 * 11.9

16.9 * 9.9

-2.0

28.9 * 28.9 * 26.3 * 26.3 * 19.1

22.0 * 14.6

18.5 * 11.8

15.6 *

-4.0

16.3 * 16.3 * 13.2 * 13.2 *

14.5

9.0

10.4

10.3 * 8.6

13.4 * 7.8

12.4 * 12.4 * 6.2

-6.0

13.5 * 13.5 * 8.1 * 8.1 * 6.9

15.9 * 15.9 * 14.5 * 14.5 * 13.5

13.5 * 9.5 * 9.5 * 7.7 * 7.7 * 8.1

25.3 * 25.3 * 19.9 * 19.9 * 16.2

16.8 * 12.9

14.9 * 10.6

13.6 * 8.0 * 8.0 * 8.8

19.8

23.4 * 15.3

19.1 * 12.3

16.3 * 10.2

14.4 * 8.7 * 8.7 * 8.9

12-13

SPECIFICATIONS

LIFTING CAPACITIES

NOTE: 1. Lifting capacity of the ZX series does not exceed

75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. (ISO

10567)

2. * Indicates load limited by hydraulic capacity.

M1G6-13-013

A: Load radius

B: Load point height

METRIC MEASURE

ZX470LCH

-3

Boom (H) 7.0 m , Arm (BE) 2.9 m, Without Bucket Shoes 600 mm

B: Load point height m

3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m 9.0 m

Unit; 1000 kg

At max. reach

@ m

7.0

6.0

4.0

2.0

(GROUND)

16.5 23.5 * 12.7 19.6 * 10.3 16.6 * 8.6 14.0 7.3 11.8 7.1 11.4 9.2

-2.0

19.9 * 19.9 * 23.9 25.0 * 16.6 21.6 * 12.6 18.4 * 10.2 15.8 * 8.5 13.5 *

-4.0

22.3 * 22.3 * 20.0 20.0 * 17.0 17.5 * 13.0 15.0 * 10.5 12.5 *

7.9 12.5 * 8.5

10.4 12.3 * 7.1

-6.0

-8.0

12.3 12.3 * 9.9 11.8 *

14.1 * 14.1 * 12.0 12.9 * 9.7 12.1 *

9.4 11.8 * 8.2

8.4 11.7 * 8.7

18.4 20.4 * 14.2 16.7 * 11.3 14.5 * 9.3 13.0 * 7.8 12.0 * 7.3 11.6 9.3

16.9 23.5 * 13.2 19.0 * 10.7 16.0 * 8.9 14.0 * 7.5 12.0 6.9 11.1 9.5

ZX520LCH

-3

Boom (H) 7.0 m , Arm (BE) 2.9 m, Without Bucket Shoes 600 mm

B: Load point height m

3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m 9.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

12.1 * 12.1 *

14.2 * 14.2 * 12.9 * 12.9 * 10.8 12.1 *

11.1 * 11.1 * 7.6

9.3 11.0 * 8.8

20.5 20.5 * 15.7 16.8 * 12.6 14.6 * 10.4 13.1 * 8.7 12.0 * 8.2 11.7 * 9.3

19.0 23.5 * 14.7 19.0 * 11.9 16.1 * 9.9 14.0 * 8.4 12.2 7.8 11.3 9.5

(GROUND)

18.6 23.4 * 14.3 19.5 * 11.5 16.6 * 9.6 14.2 8.2 12.0 8.0 11.7 9.2

-2.0

20.6 * 20.6 * 24.8 * 24.8 * 18.7 21.4 * 14.2 18.3 * 11.5 15.7 * 9.6 13.4 *

-4.0

21.9 * 21.9 * 19.7 * 19.7 * 17.2 * 17.2 * 14.6 14.8 * 11.8 12.3 *

9.0 12.5 * 8.4

11.8 12.2 * 7.0

-5.0

13.6 * 13.6 * 11.4 * 11.4 * 5.9

12-14

SPECIFICATIONS

LIFTING CAPACITIES

NOTE: 1. Lifting capacity of the ZX series does not exceed

75% of tipping load with the machine on firm, level ground or 87 % of full hydraulic capacity. (ISO

10567)

2. * Indicates load limited by hydraulic capacity.

M1G6-13-013

A: Load radius

B: Load point height

METRIC MEASURE

ZX470LCH

-3

Boom (BE) 6.3 m , Arm (BE) 2.5 m, Without Bucket Shoes 600 mm

A: Load radius

B: Load point height m

5.0 m 6.0 m 7.0 m

8.0

6.0

4.0

2.0

14.3 * 14.3 *

16.5 * 16.5 * 14.9 * 14.9 * 12.0

18.8

17.3

20.3 *

23.5 *

14.4

13.4

17.1 *

19.2 *

11.4

10.8

(GROUND)

16.7

-2.0

-4.0

-6.0

16.8

23.7 * 12.9

21.2 * 12.9

19.7 * 10.4

17.9 * 10.5

-8.0

13.9 *

15.1 * 9.3

16.4 * 9.0

16.7 * 8.7

15.0 *

8.0 m

Unit; 1000 kg

At max. reach

@ m

12.6 * 12.6 * 6.4

10.1

11.9 * 7.8

13.8 * 8.6

14.4

8.0

12.2 *

12.9 *

8.5

8.6

14.2

8.3

9.6

13.4

8.3

13.6 * 7.5

ZX520LCH

-3

Boom (BE) 6.3 m , Arm (BE) 2.5 m, Without Bucket Shoes 600 mm

B: Load point height m

3.0 m 4.0 m 5.0 m

A: Load radius

6.0 m 7.0 m 8.0 m

Unit; 1000 kg

At max. reach

@ m

8.0

6.0

4.0

2.0

14.3 * 14.3 *

16.6 * 16.6 * 15.0 * 15.0 * 13.3

13.9 *

12.5 * 12.5 * 6.5

11.1

11.9 * 7.8

20.5 * 20.5 * 16.0

17.2 * 12.7

15.2 * 10.4

13.8 * 9.5

12.2 * 8.5

19.5

23.6 * 15.0

19.3 * 12.1

16.4 * 10.0

14.5 * 9.0

13.1

8.6

(GROUND)

18.9

23.7 * 14.5

19.7 * 11.8

16.7 * 9.8

-2.0

28.2 * 28.2 * 24.9 * 24.9 * 19.0

21.1 * 14.6

17.8 * 11.8

14.9 *

-3.0

21.7 * 21.7 * 18.6 * 18.6 * 14.8

15.6 *

14.4 * 9.4

10.9

12.7

13.7 * 8.3

13.6 * 7.4

13.1 * 6.7

12-15

SPECIFICATIONS

SOUND LEVEL RESULTS

(2000/14/EC)

LwA: sound-power level of airborne noise

LpA: sound level at operator’s station

ZAXIS450

-3

, 470H

-3

, 450LC

-3

470LCH

-3

, 500LC

-3

, 520LCH

-3

LwA

106

Unit: dB(A)

LpA

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

NOTE: The acceleration is measured in accordance with

ISO 2631/1; ISO 5349 and SAE J1166.

12-16

OPTIONAL ATTACHMENTS AND DEVICES

HYDRAULIC BREAKER

Select a breaker 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 and breaker, and perform the required checks and/or inspection before connecting the breaker to the arm.

IMPORTANT: Precautions for connecting breaker piping.

• Do not allow impurities to enter into the system when switching the breaker with the bucket.

• Before attaching the hydraulic breaker, be sure to loosen air breather plug (3), located on the top of cap assembly (2), to release internal pressure and to drain the trapped hydraulic oil.

Then, remove cap assembly (2).

Install the breather fitting and the breaker rubber hose before opening valve (1).

• When the breaker is not used, apply the cover to the pipe opening on the arm top and install the plug into the hose end of the breaker to prevent impurities from entering the system.

Be sure to provide spare covers and plugs in the tool box so that they will be available when needed.

• After connecting, check the connecting seal fitting for oil leakage, and pipe clamp bolts for looseness.

Close Open

Valve

M1J1-13-001

13-1

OPTIONAL ATTACHMENTS AND DEVICES

WORK MODE

1. When the basic screen displays, push key F1 and display the work mode screen.

2. Push the key located under an attachment mark to be used in order to select the attachment.

• Digging Mode

• Breaker 1 Mode

• Breaker 2 Mode

• Breaker 3 Mode

F1 Key

Basic Screen

M1J1-01-002

Breaker 1

Mode

Breaker 2

Mode

Breaker 3

Mode

M1J5-01-003

Work Mode

Digging Mode

Description

Designed for general digging and truck loading.

Breaker 1 Mode✽1 (Initial Setting Flow Rate 200L/min)

Breaker 2 Mode✽1 (Initial Setting Flow Rate 250L/min)

Breaker 3 Mode✽1 (Initial Setting Flow Rate 280L/min)

Select this mode switch when using MITSUBISHI MKB2550V, FU-

RUKAWA F-30, F-35 or OKADA TOP 300 respectively.

Select this mode switch when using NPK E-220, FURUKAWA

F-45, MITSUBISHI MKB300V or OKADA OUB 324 respectively.

Select this mode switch when using HITACHI HSB90S, NPK E-225,

OKADA OUB 330, 524 or MITSUBISHI MKB4000V respectively.

✽

1 When using hydraulic crusher, select the breaker mode 1, 2, or 3 when the flow rate of the crusher corresponds to the breaker mode 1, 2, or 3.

NOTE: The manufacturer of the hydraulic breaker may change the hydraulic breaker specifications without giving notice. Contact your nearest Hitachi dealer for any questionable points.

13-2

OPTIONAL ATTACHMENTS AND DEVICES

BREAKER OPERATION

The breaker can be operated using attachment pedal (1) located on the right front of the seat, as illustrated.

WARNING: Be sure to lock attachment pedal (1) with pedal lock (2) when the attachment pedal is not in use.

WARNING: Before operating the hydraulic breaker, be sure to select the breaker mode using work mode key.

Failure to do so, damage to hydraulic components and/or the hydraulic breaker may result.

Select hydraulic oil flow rate breaker mode key to the proper position depending on the mode of hydraulic breaker employed.

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.

Flow Rate by Breaker Mode

Breaker 1 Mode: 200 L/min

Breaker 2 Mode: 250 L/min

Breaker 3 Mode: 280 L/min

M1J1-01-026

Locked Attachment Pedal

M1J1-13-002

13-3

OPTIONAL ATTACHMENTS AND DEVICES

IMPORTANT: Turn the boom mode switch (3) [OFF] when operating a hydraulic breaker. If the boom mode switch (3) is turned [ON], boom-lowering force is reduced so that the designed hydraulic breaker power cannot be sufficiently utilized.

1. Select the proper hydraulic breaker mode on work mode screen (6) depending on the necessary oil flow rate of hydraulic breaker employed. Refer to the “work mode” section on page 13-2 for work mode setting procedures.

2. Move pedal lock (2) forward to unlock attachment pedal

(1).

3. Push down on attachment pedal (1) to operate the breaker.

WARNING: If stopper bolt (5) does not contact to bracket (4), the attachment pedal falls backward and the hydraulic oil flows backward. Damage to the hydraulic breaker may result.

4. Remove foot from attachment pedal (1) to stop the breaker.

5. Always keep attachment pedal (1) locked with pedal lock

(2) when the attachment pedal is not in use.

M1J1-03-001

M1J1-01-020

M1J5-05-003

Locked Attachment pedal

M1J1-13-002

Unlocked Attachment pedal

M1J1-13-003

13-4

OPTIONAL ATTACHMENTS AND DEVICES

PRECAUTIONS FOR BREAKER OPERATION

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. Observe the following precautions and take any other precautions necessary to prevent accidents and machine damage from occurring.

• Avoid hitting objects with breaker.

The breaker is heavier than the bucket, causing the breaker to lower faster.

Take care not to hit any objects with breaker. Doing so will result in damage to the breaker, the front attachment, and/or the upperstructure. Always move (lower) the breaker slowly to position the tip of the chisel on the object to be broken before starting breaker operation.

• Do not use the breaker and/or the swing function to move objects. Damage to the boom, arm, and/or breaker may result.

• To prevent cylinder/machine damage, do not operate the breaker with the hydraulic cylinder rod fully retracted or fully extended.

• Stop operation if breaker hydraulic hoses jump abnormally. Change in breaker accumulator pressure or a damaged accumulator will cause abnormal hose jumping and may cause breaker and/or machine damage.

Immediately contact your authorized dealer if this happens.

WRONG

M104-05-055

WRONG

M104-05-056

WRONG

Hose jumping abnormally

M104-05-057

Accumulator

Hose jumping abnormally

M104-05-056

13-5

OPTIONAL ATTACHMENTS AND DEVICES

• Do not operate the breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components.

WRONG

Rod

• Do not use breaker for lifting operation. The machine tipping over and/or breaker damage may result.

WRONG

M104-05-059

• Do not operate the breaker to the side of the machine.

The machine may become unstable and undercarriage component life may shorten as a result from operating the breaker to the side of the machine.

RIGHT

M104-05-060

WRONG

RIGHT

WRONG

M104-05-061

• Operate the hydraulic excavator carefully to avoid hitting the boom.

Watch Out!

Take care not to hit the boom with the breaker

M104-05-062

13-6

OPTIONAL ATTACHMENTS AND DEVICES

• Do not operate breaker with the arm positioned vertically.

Excessive vibration to the arm cylinder will occur, causing oil leakage.

• Press the breaker so that the chisel (the axis) is positioned and thrusted perpendicular to the object.

RIGHT WRONG

M147-05-013

M147-05-014

• Do not operate the breaker continuously longer than one minute. Excessive chisel wear will result. If an object could not be broken within one minute, apply the chisel to other locations, less than one minute for each location.

• Raising the front part of the undercarriage by pressing down the breaker may cause damage to the front attachment. Although raising the front edge of the undercarriage up to 150 mm (6 in) is tolerable, do not practice this method more than necessary. Never raise the front edge of the undercarriage higher than 150 mm (6 in) by pressing the breaker down.

Pressing

Down

Raising 100 to

150 mm

If an object could not be broken within one minute, apply the chisel to other l o c at i o n s, l e s s t h a n o n e minute for each location.

M147-05-015

M147-05-016

13-7

OPTIONAL ATTACHMENTS AND DEVICES

• Do not hit one place for longer than one minute.

If the hydraulic breaker is allowed to hit one place for a long time, oil pressure may increase and accumulator damage may result. If a material is too hard to be broken in one minute, immediately change the hitting location.

Try to hit a breakable edge first to make the work more efficient.

If a material is too hard to be b r o k e n i n o n e m i n u t e , immediately change the hitting location.

Break from an edge side.

M116-05-011

• Avoid blank strokes of the chisel.

After depressing a material with the hydraulic breaker weight, start hitting. Blank strokes of the chisel may cause overheating of oil and damage to the accumulator.

Blank stroke

WRONG RIGHT

M116-05-005

Depression

M116-05-006

• Do not wedge the breaker chisel into material.

If the breaker chisel is used to wedge material, wear and damage to the chisel and wear bushing may result.

WRONG

• Hit perpendicularly to the material surface.

Unless the material surface is hit perpendicularly with the chisel, the bolts and chisel may be broken.

Do not wedge the breaker chisel

M116-05-007

Do perpendicularly to the material surface

M116-05-008

13-8

OPTIONAL ATTACHMENTS AND DEVICES

BREAKER MAINTENANCE

Change Hydraulic Oil and Replace Hydraulic Oil Tank Filter

Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to deteriorate the hydraulic oil quickly. For this reason, hydraulic oil must be changed and the hydraulic oil tank filter must be replaced more often than the machine attached with a bucket. Failure to do so may result in damage to the breaker, hydraulic oil pump, and other hydraulic system components. Recommended changing intervals are shown below. (For filter replacement and oil changing procedures, refer to the “Hydraulic System” in the “MAINTE-

NANCE” Section.)

Hydraulic Oil

Filter Element

Changing Interval (hours)

Machine with

Hydraulic Breaker

600*

100*

Machine with

Ordinary Bucket

1500 or 2500 or 4000

1000

NOTE: *The above figures are for 100% breaker time share.

When the breaker time share is less, changing intervals can be extended as shown in the diagram below.

Be sure to replace elements when breaker has been operated for 100 hours continuously.

Breaker

Time

Sharing

(%)

Time to replace ﬁlter element

Time to change hydraulic oil 1500 hours changing interval

Time to change hydraulic oil 2500 hours changing interval

Time to change hydraulic oil 4000 hours changing interval

Changing Interval (Hours)

13-9

M1J1-13-011

OPTIONAL ATTACHMENTS AND DEVICES

Breaker hour meter (1) is located in the operator’s cab on the right control panel. This hour meter (1) operates when the breaker pedal is depressed. Obtain the average breaker operation ratio according to the following formula.

Average breaker operation ratio (%) = Breaker operation hours/Excavator operation hours = (Present breaker hour meter reading – Breaker hour meter reading when the breaker was previously removed)/(Present hour meter reading – hour meter reading when the breaker was previously removed)

In case the machine is fully engaged in breaker operation

(breaker operation ratio:100%), perform the maintenance of hydraulic oil, the full flow filter element, and the breaker return filter based on the reading of the breaker hour meter.

M1J1-03-001

Breaker Hour Meter

M1J1-13-008

Average breaker operation ratio (%)

Excavator operation hours

Breaker operation hours

(Present breaker hour meter reading – breaker hour meter reading when the breaker was previously removed)

13-10

OPTIONAL ATTACHMENTS AND DEVICES

REPLACE BREAKER CIRCUIT RETURN OIL FILTER

WARNING: Hydraulic oil may be hot. Wait for oil to cool before starting work.

1. Park the machine on a level surface.

Lower the breaker to the ground.

2. Leave the machine for a while after stopping operation.

After the oil temperature is cooled, push air bleed valve

(10) to bleed air from the hydraulic oil tank.

3. Loosen drain plug (9) to drain hydraulic oil from filter case (7).

4. Remove bolts (1) to remove cover assembly (4).

5. Remove element (6).

Inspect the element (6) for metal debris to help in early detection of failures.

6. Install a new element.

7. Inspect O-rings (2), (3), (5) and (8) for any damage.

Replace damaged O-rings.

8. Confirm that O-rings (2) and (3) are securely in the grooves.

Install cover assembly (4) so that arrows (A) on the cover point left, as shown in the figure.

9. Tighten drain plug (9).

Tightening Torque: 44 N•m (4.5 kgf•m, 32.5 lbf•ft)

10. Tighten bolts (1).

Tightening Torque: 127 to 147 N•m

(13 to 15 kgf•m, 94 to 108 lbf•ft)

Cab

Front

Breaker-Circuit-Return-Oil Filter

M1J1-07-006

M111-05-009

(A810135)

(A810095)

(4357445)

(954493)

M111-05-011

13-11

OPTIONAL ATTACHMENTS AND DEVICES

HYDRAULIC CRUSHER

Machine stability, applicable hydraulic oil pressure and oil quantity for crusher, etc. must be examined when selecting a crusher.

Be sure to consult your authorized dealer when selecting a crusher.

For operational instructions, refer to the crusher instruction manual.

Operation

The crusher can be operated using attachment pedal (1) located on the right front of the seat, as illustrated.

WARNING: Be sure to lock attachment pedal (1) with pedal lock (2) when the attachment pedal is not in use.

When operating a hydraulic crusher, do not step on attachment pedal (1) rearward. Damage to the hydraulic crusher may result.

1. Select the proper hydraulic breaker mode on work mode screen (3) depending on the necessary oil flow rate of hydraulic crusher employed. Refer to the “work mode “ section on page 13-2 for work mode setting procedures.

2. Move pedal lock (2) forward to unlock attachment pedal

(1).

Note that if the attachment mode is selected, open/close speed of the crusher may become slow.

3. Push down on attachment pedal (1) either forward or backward to open or close the crusher.

4. Remove foot from attachment pedal (1) to stop the crusher.

5. Always keep attachment pedal (1) locked with pedal lock

(2) when attachment pedal (1) is not in use.

Work Mode Screen

M1J1-01-026

M1J5-05-003

Locked Attachment Padal

M1J1-13-002

13-12

Fully Tighten the

Stopper Bolt

Unlocked Attachment Padal

M1J1-13-006

OPTIONAL ATTACHMENTS AND DEVICES

STOP VALVE OPERATION

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.

• When using a hydraulic breaker, turn the stop valves to the positions as illustrated to the right.

• When using a hydraulic crusher, turn the stop valves to the positions as illustrated to the right. After using the hydraulic crusher, be sure to turn the stop valves back to the breaker operation positions.

Stop Valve 2

View A

Stop Valve 1

Secondary Relief

Valve

Stop Valve 2

M1J1-13-009

Breaker Crasher

Stop Valve 1

Stop Valve 2

M16J-12-025

13-13

OPTIONAL ATTACHMENTS AND DEVICES

THREE-WAY-VALVE OPERATION

(Machines equipped with the piping common to hydraulic breaker and crusher operation)

• 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.

• Turn the three-way-valve to the position as shown in the lower right illustration when using a hydraulic crusher.

After using a hydraulic crusher, be sure to turn the threeway-valve back to the hydraulic breaker position (as shown in the upper right illustration).

Breaker

Crasher

M16J-12-005

FLOW COMBINING VALVE OPERATION

The flow combining valve is located under the front outside of the pump chamber.

• Turn the flow combining valve to the position as shown in the left- right illustration when using a hydraulic breaker/ crusher so that the oil flows from the 2 pumps are not combined.

• Turn the flow combining valve to the position as shown in the right-right illustration when combining the oil flows from the 2 pumps for increasing the flow rate. When the oil flows from the 2 pumps are not combined, be sure to turn the flow combining valve back to the hydraulic breaker/crusher position (as shown in the left- right illustration).

Hydraulic Breaker/Crusher

Position

Three-way-valve

M16J-12-006

2 Pump Combined

Position

M1J1-13-010

13-14

Flow Combining Valve

M1J1-13-007

OPTIONAL ATTACHMENTS AND DEVICES

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. Also, falling or flying objects may hit the cab or other part of the machine. Observe the following precautions and take any other precautions necessary to prevent accidents and machine damage from occurring.

• Do not allow the machine’s weight to be supported by the crusher or bucket cylinder with the bucket cylinder fully extended or retracted. Doing so may damage the front attachment. In particular, avoid doing so with the bucket cylinder fully extended, as the front attachment will be easily damaged.

Take care to prevent this from happening when dismantling foundation structures using the crusher.

• Do not attempt to perform crushing on either side of the machine. Always perform crushing operations to the fore or rear, parallel with the tracks. Otherwise, tipping over may occur.

WRONG

M107-05-046

WRONG

M107-05-047

13-15

OPTIONAL ATTACHMENTS AND DEVICES

• When operating the crusher up high with the boom fully raised, be careful of falling objects.

WRONG

• When operating the crusher on a floor in a building, first confirm that the floor has sufficient strength to support the load caused by crushing, in addition to the machine weight.

• Always operate the crusher on a stable, level surface, not on a slope or on crushed scraps.

• Do not use the crusher to haul or load crushed scraps.

• If a multiple number of attachments, such as crusher and bucket, or crusher and breaker, are used, replacing them with each other at intervals, impurities are more apt to enter the hydraulic system and the hydraulic oil deteriorates quickly. For this reason, replace the hydraulic oil tank filter and change the hydraulic oil at the intervals specified in the breaker time sharing diagram in the previous section.

Read the breaker time sharing diagram supposing that time sharing percentage of attachment (s) other than the crusher is that of the breaker.

• Always remove the crusher from the excavator before transporting the machine. Do not fully extend the bucket cylinder when transporting, as this may damage the front attachment, when vibrations arise during transportation.

13-16

M107-05-048

WRONG

M107-05-049

INDEX

AM/FM Radio Operation ...........................................................1-75

ASSEMBLING .................................................................................... 6-1