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PART NO.
ENMJAC-1-1
ZX470-5 • 870-5 class HYDRAULIC EXCAVATOR
Operator's Manual
OPERATOR'S MANUAL
470-5 class
470-5G · 470LC-5G · 470H-5G 470LCH-5G · 470R-5G · 470LCR-5G
870-5 class
870-5G · 870LC-5G · 870H-5G 870LCH-5G · 870LCR-5G
Hydraulic Excavator URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (E) 2011, 11
ENMJAC-1-1
This book is printed on recycled paper.
Serial No. 0050001 and up
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 standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: –20 °C to 45 °C (–4 °F to 113 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest Hitachi dealer. 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. 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. Be sure to use fuel that complies with your local standard. Also use of fuel that complies with solid contamination level of class 18/16/13 of ISO4406-1999 (solid contamination includes dust) is recommended. If the fuel specified above is not used, a problem may arise on the engine. Consult your nearest Hitachi dealer.
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. PRIOR TO OPERATING THIS MACHINE, INCLUDING SATELLITE COMMUNICATION SYSTEM, IN A COUNTRY OTHER THAN A COUNTRY OF ITS INTENDED USE, IT MAY BE NECESSARY TO MAKE MODIFICATIONS TO IT SO THAT IT COMPLIES WITH THE LOCAL REGULATORY STANDARDS (INCLUDING SAFETY STANDARDS) AND LEGAL REQUIREMENTS OF THAT PARTICULAR COUNTRY. PLEASE DO NOT EXPORT OR OPERATE THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS INTENDED USE UNTIL SUCH COMPLIANCE HAS BEEN CONFIRMED. PLEASE CONTACT HITACHI CONSTRUCTION MACHINERY CO., LTD. OR ANY OF OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU HAVE ANY QUESTIONS CONCERNING COMPLIANCE.
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. ©2011 Hitachi Construction Machinery Co., Ltd. All rights reserved.
INDEX
MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE T MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
ENMJAC-1-1
STORAGE TROUBLESHOOTING SPECIFICATIONS INDEX
CONTENTS MACHINE NUMBERS..........................................................1 SAFETY........................................................................... S-1 Recognize Safety Information.....................................................S-1 Understand Signal Words..............................................................S-1 Follow Safety Instructions.............................................................S-2 Prepare for Emergencies................................................................S-3 Wear Protective Clothing..............................................................S-3 Protect Against Noise.....................................................................S-4 Inspect Machine...............................................................................S-4 General Precautions for Cab.........................................................S-5 Use Handholds and Steps.............................................................S-6 Adjust the Operator's Seat............................................................S-6 Ensure Safety Before Rising from or Leaving Operator’s Seat............................................................................S-7 Fasten Your Seat Belt.......................................................................S-7 Move and Operate Machine Safely............................................S-8 Operate Only from Operator's Seat...........................................S-8 Jump Starting....................................................................................S-9 Keep Riders off Machine................................................................S-9 Precautions for Operations........................................................ S-10 Investigate Job Site Beforehand.............................................. S-11 Install OPG Guard.......................................................................... S-12 Provide Signals for Jobs Involving Multiple Machines.... S-13 Confirm Direction of Machine to Be Driven......................... S-13 Drive Machine Safely.................................................................... S-14 Avoid Injury from Rollaway Accidents................................... S-16 Avoid Injury from Back-Over and Swing Accidents.......... S-17 Keep Person Clear from Working Area.................................. S-18 Never Position Bucket Over Anyone...................................... S-18 Avoid Undercutting...................................................................... S-19 Avoid Tipping.................................................................................. S-19 Never Undercut a High Bank..................................................... S-20 Dig with Caution............................................................................ S-20 Operate with Caution.................................................................. S-20 Avoid Power Lines......................................................................... S-21 Precautions for Lightning........................................................... S-21 Object Handling............................................................................ S-22 Protect Against Flying Debris................................................... S-22 Park Machine Safely...................................................................... S-23 Handle Fluids Safely−Avoid Fires............................................ S-23 Transport Safely............................................................................. S-24 Practice Safe Maintenance......................................................... S-25 Warn Others of Service Work.................................................... S-26 Support Machine Properly......................................................... S-26 Stay Clear of Moving Parts......................................................... S-27 Prevent Parts from Flying........................................................... S-27 Store Attachments Safely........................................................... S-28 Prevent Burns.................................................................................. S-28 Replace Rubber Hoses Periodically......................................... S-29 Avoid High-Pressure Fluids........................................................ S-29 Prevent Fires.................................................................................... S-30 Evacuating in Case of Fire........................................................... S-32 Beware of Exhaust Fumes.......................................................... S-32 Precautions for Welding and Grinding.................................. S-33 Avoid Heating Near Pressurized Fluid Lines........................ S-34
Avoid Applying Heat to Lines Containing Flammable Fluids............................................................................................ S-34 Precautions for Handling Accumulator and Gas Damper........................................................................................ S-34 Remove Paint Before Welding or Heating............................ S-35 Beware of Asbestos and Silicon Dust and Other Contamination.......................................................................... S-35 Prevent Battery Explosions........................................................ S-36 Service Air Conditioning System Safely................................ S-36 Handle Chemical Products Safely............................................ S-37 Dispose of Waste Properly.......................................................... S-37 Never Ride Attachment............................................................... S-38 Precautions for Communication Terminal............................ S-38 Precaution for Communication Terminal Equipment...... S-39 SAFETY SIGNS.............................................................. S-41 COMPONENTS NAME..................................................... 1-1 Components Name.........................................................................1-1 GETTING ON/OFF THE MACHINE.................................. 1-2 Getting ON/OFF the Machine......................................................1-2 OPERATOR’S STATION................................................... 1-3 Cab Features (Std. Model).............................................................1-3 Cab Features (with Attachment).................................................1-4 Multi Function Monitor..................................................................1-5 Default Setting..................................................................................1-6 Basic Screen........................................................................................1-7 How to Use Screens.........................................................................1-8 Displaying Basic Screen............................................................1-8 Hour Meter................................................................................. 1-11 Clock............................................................................................. 1-11 Fuel Gauge................................................................................. 1-11 Coolant Temperature Gauge............................................... 1-12 Operating Status Icon Display............................................. 1-12 Security Functions........................................................................ 1-13 Input Password......................................................................... 1-13 Extending Password Duration Time.................................. 1-14 Alarm Occurrence Screen........................................................... 1-15 Remedy............................................................................................. 1-17 Main Menu....................................................................................... 1-20 Air Conditioner............................................................................... 1-21 Circulation Air Mode............................................................... 1-21 Air Conditioner ON/OFF........................................................ 1-21 Radio.................................................................................................. 1-22 Work Mode...................................................................................... 1-23 Attachment Selection............................................................ 1-23 Mail (Optional)................................................................................ 1-24 Setting Menu.................................................................................. 1-26 Date and Time................................................................................ 1-27 Time Adjustment..................................................................... 1-27 Date Adjustment...................................................................... 1-29 Display Mode Setting............................................................. 1-31 Attachment Adjust........................................................................ 1-33 Flow Rate Adjustment............................................................ 1-33 Attachment Name Input............................................................. 1-35 Password Change.......................................................................... 1-37
CONTENTS Sub Meter......................................................................................... 1-41 Rear View Camera Monitor (Optional)................................... 1-43 Rear View Camera ON/OFF................................................... 1-43 Brightness Adjustment................................................................ 1-45 Language Settings........................................................................ 1-47 Lists of Display Language........................................................... 1-49 Unit Selection................................................................................. 1-50 Display Item Selection (Rear View Camera OFF)................ 1-52 Main Menu Sequence Change................................................. 1-54 Information Menu......................................................................... 1-56 Operation......................................................................................... 1-57 Breaker Operation................................................................... 1-57 Attachment Operation........................................................... 1-59 Travel Operation....................................................................... 1-61 Actual Operation...................................................................... 1-63 Maintenance................................................................................... 1-65 Maintenance Notice................................................................ 1-65 Time Remains and Maintenance Interval........................ 1-67 Troubleshooting............................................................................ 1-69 Monitoring....................................................................................... 1-71 Switch Panel.................................................................................... 1-73 Return to Previous Screen (Monitor)................................ 1-74 Return to Basic Screen (Monitor)....................................... 1-74 Select/Confirm Switch (Monitor)....................................... 1-74 Temperature Control Switch/Mode Switch (Air Conditioner)......................................................................... 1-74 AUTO/OFF Switch/Fan Switch (Air Conditioner)........... 1-74 AM/FM Selector/Tuning Switch (Radio)........................... 1-75 Power Switch/Volume Control Knob (Radio)................. 1-75 Engine Control Dial................................................................. 1-75 Auto-Idle Switch....................................................................... 1-76 Travel Mode Switch................................................................. 1-76 Mode Switch.............................................................................. 1-77 ECO (Economy) Mode............................................................ 1-77 PWR (Power) Mode.................................................................. 1-77 H/P (High Power) Mode......................................................... 1-77 Work Light Switch.................................................................... 1-78 Wiper/Washer Switch............................................................. 1-79 Numeric Keypad....................................................................... 1-80 Switch Panel (for Optional Equipment)................................. 1-81 Travel Alarm Deactivation Switch (Optional) (1).......... 1-82 Rear Light Switch (Optional) (2).......................................... 1-82 Boom Mode Switch (3)........................................................... 1-82 Swing Alarm Deactivation Switch (Optional) (4).......... 1-82 Auto-Lubrication Switch (5)................................................. 1-83 Auto-Lubrication Selector Switch (Optional) (6).......... 1-83 Seat Heater Switch (Optional) (7)....................................... 1-83 Key Switch........................................................................................ 1-84 Power Boost Switch...................................................................... 1-84 Horn Switch..................................................................................... 1-84 Cigar Lighter.................................................................................... 1-85 Using Cigar Lighter ................................................................ 1-85 Using Cigar Lighter Port as External Power Source..... 1-85 Cab Light Switch............................................................................ 1-86 Installing Fire Extinguisher (Optional)................................... 1-86 Pilot Control Shut-Off Lever...................................................... 1-87
Handle (Emergency Engine Stop)........................................... 1-88 Engine Stop Switch (for Maintenance)............................. 1-88 Fuse Box............................................................................................ 1-89 Fuse Box 1................................................................................... 1-89 Fuse Box 2................................................................................... 1-89 Auto Air Conditioner.................................................................... 1-90 Features....................................................................................... 1-90 Components Name................................................................. 1-91 Controller Part Name and Function.................................. 1-92 Cab Heater Operation............................................................ 1-94 Cooling Operation................................................................... 1-95 Defroster Operation................................................................ 1-96 Cool Head/Warm Feet Operation....................................... 1-96 Tips for Optimal Air Conditioner Usage................................ 1-97 For Rapid Cooling.................................................................... 1-97 When Windows Become Clouded..................................... 1-97 Off-Season Air Conditioner Maintenance....................... 1-97 AM/FM Radio Operation............................................................. 1-98 Controls on the Radio............................................................. 1-98 Tuning Procedure.................................................................... 1-98 Station Presetting Procedure............................................... 1-99 Station Auto-Presetting Procedure.................................1-100 TONE Control...........................................................................1-101 Audio Input (Optional)..............................................................1-102 Audio Input Selection..........................................................1-102 Connecting Audio Device...................................................1-102 Volume Control of Audio Device......................................1-102 Cab Door Release Lever............................................................1-103 Opening/Closing and Removing Cab Inside Window...1-104 Opening/Closing Upper Front Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)...........................................1-105 Opening Upper Front Window.........................................1-105 Removing and Storing Lower Front Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)....................1-106 Removing and Storing Lower Front Window..............1-106 Opening Side Windows.............................................................1-107 Opening/Closing Overhead Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)...........................................1-108 Opening/Closing Overhead Window (Clear Hatch: If Equipped).................................................................................1-109 Emergency Exit............................................................................1-110 Adjusting the Seat.......................................................................1-111 Backrest Adjustment............................................................1-111 Seat Fore-Aft Adjustment...................................................1-111 Weight Adjustment...............................................................1-111 Height Adjustment................................................................1-111 Console and Seat Fore-Aft Adjustment.........................1-112 Seat Depth Adjustment.......................................................1-112 Inclination Adjustment........................................................1-112 Armrest Adjustment.............................................................1-112 Adjusting Operator's Seat (Air Suspension Type) (Optional)..................................................................................1-113 Adjusting Seat Height..........................................................1-113 Console and Seat Fore-Aft Adjustment.........................1-113 Seat Fore-Aft Adjustment...................................................1-113 Suspension Adjustment......................................................1-113
CONTENTS Seat Depth Adjustment.......................................................1-114 Inclination Adjustment........................................................1-114 Backrest Adjustment............................................................1-114 Armrest Adjustment.............................................................1-114 Installation and Adjustment of Mirrors...............................1-115 Seat Belt..........................................................................................1-116 Seat Belt....................................................................................1-116 BREAK-IN........................................................................ 2-1 Observe Engine Operation Closely............................................2-1 Every 10 Hours or Daily..................................................................2-1 After the First 50 Hours..................................................................2-1 After the First 100 Hours................................................................2-1 OPERATING THE ENGINE............................................... 3-1 Inspect Machine Daily Before Starting.....................................3-1 Before Starting Engine...................................................................3-2 Starting the Engine..........................................................................3-3 Check Instruments After Starting...............................................3-7 Using Booster Batteries..................................................................3-8 Stopping the Engine.................................................................... 3-10 DRIVING THE MACHINE................................................. 4-1 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.....................................4-6 Towing Machine a Short Distance..............................................4-7 Operating in Water or Mud...........................................................4-8 Parking the Machine on Slopes...................................................4-9 Parking the Machine.......................................................................4-9 OPERATING THE MACHINE............................................ 5-1 Control Lever (ISO Pattern)...........................................................5-1 Control Lever (HITACHI Pattern) (Optional).............................5-2 Attachment Pedal (Hydraulic Breaker) (Optional)................5-3 Attachment Pedal (Hydraulic Crusher) (Optional)................5-4 Pilot Control Shut-Off Lever.........................................................5-5 Warming Up Operation..................................................................5-6 Engine Speed Control.....................................................................5-7 Auto-Idle..............................................................................................5-8 Work Mode...................................................................................... 5-10 Power Boost Switch...................................................................... 5-13 Mode Switch................................................................................... 5-14 Operating Backhoe....................................................................... 5-15 Precaution for Arm Roll-In/Bucket Roll-In Combined Operation.................................................................................... 5-15 Grading Operation........................................................................ 5-16 Do Not Strike the Ground with Bucket Teeth...................... 5-17 Avoid Hammer Work.................................................................... 5-17 Avoid Abusive Operation........................................................... 5-18 Avoid Side Load the Bucket....................................................... 5-18 Do Not Use Wide Track Shoes on Rough Ground.............. 5-19 Object Handling --- If Equipped............................................... 5-20 Hydraulic Breaker and Hydraulic Crusher............................. 5-22
Precautions for Breaker Operation.......................................... 5-25 Precautions for Crusher Operation......................................... 5-32 Attachment...................................................................................... 5-35 How to Lower Boom In Case of Emergency and When Engine Stops.............................................................................. 5-37 Precautions for After Operations............................................. 5-38 TRANSPORTING............................................................. 6-1 Transporting by Road.....................................................................6-1 Loading/Unloading on a Trailer..................................................6-2 Fastening Machine for Transporting.........................................6-4 Unloading...........................................................................................6-4 MAINTENANCE............................................................... 7-1 Correct Maintenance and Inspection Procedures................7-1 Check the Hour Meter Regularly.................................................7-3 Use Correct Fuels and Lubricants...............................................7-3 Layout...................................................................................................7-4 Maintenance Guide Table..............................................................7-6 Preparations for Inspection and Maintenance......................7-8 Hood and Access Covers................................................................7-9 Battery Disconnect Switch (Optional).................................... 7-11 Daily Check...................................................................................... 7-13 Maintenance Guide...................................................................... 7-14 Periodic Replacement of Parts.................................................. 7-20 Kind of Oils....................................................................................... 7-21 A. Greasing....................................................................................... 7-25 Front Joint Pins......................................................................... 7-25 Swing Bearing........................................................................... 7-27 Swing Internal Gear................................................................ 7-28 Electric Grease Gun (Optional)................................................. 7-29 Components Name................................................................. 7-32 Battery Charger Operation................................................... 7-33 Normal Charging Method..................................................... 7-34 Installing/Removing Battery Pack...................................... 7-34 Power Source............................................................................. 7-34 Preparation for Using Electric Grease Gun..................... 7-36 Greasing Method..................................................................... 7-37 After Using Grease Gun......................................................... 7-38 Lubricator (Optional).................................................................... 7-39 Greasing Method..................................................................... 7-39 Grease Container Replacement.......................................... 7-41 B. Engine........................................................................................... 7-43 Check Engine Oil Level........................................................... 7-43 Change Engine Oil, Replace Engine Oil Filter................ 7-44 C. Transmission............................................................................... 7-47 Pump Transmission (ZX870-5 class).................................. 7-47 Swing Reduction Gear........................................................... 7-49 Travel Reduction Gear............................................................ 7-51 D. Hydraulic System...................................................................... 7-53 Inspection and Maintenance of Hydraulic Equipment.... 7-53 Check Hydraulic Oil Level..................................................... 7-56 Water Drain from Hydraulic Oil Tank................................. 7-57 Change Hydraulic Oil.............................................................. 7-58 Suction Filter Cleaning........................................................... 7-58 Bleed Air from the Hydraulic System................................ 7-61 Replacement of Full-Flow Filter.......................................... 7-62
CONTENTS Replace Pump Drain Filter.................................................... 7-63 Replace Pilot Oil Filter............................................................ 7-64 Replace Air Breather Element.............................................. 7-66 Check Hoses and Lines.......................................................... 7-67 E. Fuel System................................................................................. 7-72 Drain Fuel Tank Sump............................................................. 7-74 Check Water Separator.......................................................... 7-75 Bleed Air from the Fuel System........................................... 7-76 Replace Fuel Main Filter......................................................... 7-77 Replace Fuel Pre-Filter............................................................ 7-78 Clean Feed Pump Strainer.................................................... 7-80 Check Fuel Hoses..................................................................... 7-81 F. Air Cleaner.................................................................................... 7-82 Clean Air Cleaner Element.................................................... 7-82 Replace Air Cleaner Outer/Inner Element....................... 7-82 G. Cooling System......................................................................... 7-84 Check Coolant Level............................................................... 7-85 Change Coolant........................................................................ 7-86 Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Core ............................................................................ 7-88 Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Front Screen............................................................. 7-88 Clean Air Conditioner Condenser...................................... 7-88 H. Air Conditioner.......................................................................... 7-89 Clean and Replace Air Conditioner Filter........................ 7-89 Check Air Conditioner............................................................ 7-91 Adjust Compressor Belt Tension......................................... 7-92 Check Looseness at Each of Fastened Areas.................. 7-92 Check at Preseason and Off-Season................................. 7-93 I. Electrical System......................................................................... 7-94 Battery.......................................................................................... 7-94 Replacing Fuses........................................................................ 7-99 J. Miscellaneous...........................................................................7-101 Check and Replace Bucket Teeth.....................................7-101 Change Bucket........................................................................7-104 Separation Type O-ring Removal Method....................7-104 Separation Type O-ring Installation Method...............7-105 Solid Type O-ring Removal Method................................7-106 Solid Type O-ring Installation Method...........................7-106 Adjust Bucket Linkage.........................................................7-107 Remove Travel Levers...........................................................7-108 Check and Replace Seat Belt..............................................7-108 Check Windshield Fluid Level............................................7-109 Check Track Sag......................................................................7-110 Clean Cab Floor......................................................................7-113 Retighten Cylinder Head Bolt............................................7-114 Inspect and Adjust Valve Clearance................................7-114 Check of Fuel Injection Timing..........................................7-114 Measure Engine Compression Pressure........................7-114 Check Starter and Alternator.............................................7-114 Check Water Pump................................................................7-114 Check and Replace Injection Nozzle...............................7-114 Check Gas Damper................................................................7-115 Check Cushion Rubber of Handrail (ZX470-5 class)......................................................................................7-115
Tightening and Retightening Torque of Nuts and Bolts.......................................................................................7-115 Check O-rings in Bucket .....................................................7-140 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS .................................................................. 9-1 Maintenance Under Special Environmental Conditions....9-1 STORAGE...................................................................... 10-1 Storing the Machine..................................................................... 10-1 Removing the Machine From Storage................................... 10-2 TROUBLESHOOTING.................................................... 11-1 Troubleshooting............................................................................ 11-1 SPECIFICATIONS.......................................................... 12-1 Specifications ZX470-5G, 470LC-5G....................................... 12-1 Working Ranges ZX470-5G, 470LC-5G.................................. 12-2 Specifications ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G.................................................................................. 12-3 Working Ranges ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G.................................................................................. 12-4 Shoe Types and Applications (ZX470-5 class)..................... 12-5 Bucket Types and Applications (ZX470-5 class)................. 12-6 Specifications ZX870-5G, 870LC-5G....................................... 12-7 Working Ranges ZX870-5G, 870LC-5G.................................. 12-8 Specifications ZX870H-5G, 870LCH-5G, 870LCR-5G......... 12-9 Working Ranges ZX870H-5G, 870LCH-5G, 870LCR-5G................................................................................12-10 Shoe Types and Applications (ZX870-5 class)...................12-11 Bucket Types and Applications (ZX870-5 class)...............12-12 INDEX............................................................................ 14-1
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 :
M157-00-001 ZX870-5 class
Product Identification Number PRODUCT IDENTIFICATION NUMBER : ZX470-5 class
M157-12-008
Engine TYPE
:
MFG. NO. : M16J-00-004
ZX470-5 class
ZX870-5 class
1
MJAC-00-001
MACHINE NUMBERS Travel Motor TYPE
:
MFG. NO. :
2
ZX470-5 class
M111-12-007
ZX870-5 class
M17V-00-002
MACHINE NUMBERS Swing Motor TYPE
:
MFG. NO. :
3
ZX470-5 class
M16J-07-007
ZX870-5 class
M1JB-00-001
MACHINE NUMBERS Hydraulic Pump TYPE
:
MFG. NO. :
Boom TYPE
ZX470-5 class
M16J-00-003
ZX870-5 class
M1J7-07-003
:
MFG. NO. :
M111-12-005
4
MACHINE NUMBERS Arm TYPE
:
MFG. NO. :
M17V-00-005
Bucket TYPE
:
MFG. NO. :
M116-12-004
5
MACHINE NUMBERS MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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6
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.
SA-688
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 do not 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.
S-1
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. Never attempt to modify or disassemble the inlet/exhaust parts and the muffler filter. Avoid giving shocks on the muffler filter by striking elements with other objects or dropping the elements. Failure to do so may affect the exhaust gas purifying device, possibly damaging it or lowering its performance. 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.
S-2
SA-003
SAFETY 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.
SA-437
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.
S-3
SA-438
SAFETY 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.
SA-434
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 "Inspect Machine Daily Before Starting" section in the operator’s manual.
SA-435
S-4
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.
S-5
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. Never get on and off the machine with tools in your hands.
SA-439
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.
S-6
SA-378
SAFETY Ensure Safety Before Rising from or Leaving 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 and/or pedal, 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.
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.
S-7
SA-237
SAFETY 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. Ensure the cab door, windows, doors and covers are securely locked. Check the mirrors and the monitor in the CAB for problems. If there is, replace the problem part(s) or clean the mirror, camera and the monitor. Refer to Rear View Monitor section on the cleaning of the camera and the monitor.
SA-426
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.
S-8
SA-444
SAFETY 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. SA-032
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.
SA-379
S-9
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.
M178-05-007
S-10
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 with 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.
S-11
SA-380
SAFETY 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 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.
M104-05-016
Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. The guard can be compliant with ROPS standards depending on the machine specifications. In order not to impair operator protective structure: Replace damaged ROPS or OPG guard. Never attempt to repair or modify the guard. ROPS: Roll Over Protective Structure OPG: Operator Protective Guard
SA-490
S-12
SAFETY Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple 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.
SA-481
Confirm Direction of Machine to Be Driven Incorrect travel pedal/lever operation may result in serious injury or 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.
SA-491
S-13
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. Do not allow personnel to stay around the machine while traveling.
A
SA-657
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 0.2 to 0.3 m (A) above the ground. If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. 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.
A
SA-658
SA-441
WRONG
SA-590
S-14
SAFETY 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.
S-15
Travel Motor M104-05-008
Arrow -mark 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 the 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 OFF and the power mode switch ECO. 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 at a reasonable distance from other machines.
SA-391
SA-2273
S-16
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.
S-17
SA-383
SA-384
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.
SA-386
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.
SA-487
S-18
SAFETY 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.
SA-488
Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. 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.
SA-012
Be careful when working on frozen ground. Temperature increases will cause the ground to become soft and make ground travel unstable.
SA-440
S-19
SAFETY Never Undercut a High Bank The edges could collapse or a land slide could occur causing serious injury or death.
SA-489
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.
SA-382
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.
SA-389
S-20
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. SA-381
Precautions for Lightning The machine is vulnerable to lightning 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.
SA-1088
S-21
SAFETY 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.
SA-014
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. Always close the front windows, doors, door windows and the overhead window when operating the machine.
SA-432
S-22
SAFETY Park Machine Safely To avoid accidents: Park machine on a firm, level surface. Lower bucket to the ground. Turn auto-idle switch OFF and power mode switch ECO. 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. SA-390
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.
SA-018
SA-019
S-23
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 and turn mode switch to ECO position. 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 tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section.
S-24
SA-395
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.
SA-028
7. Remove the key from the key 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 the machine unattended. If the machine must be raised, maintain a 90 to 110˚ 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.
S-25
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.
SA-037
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.
SS3076175
SS2045102
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.
S-26
SA-527
SAFETY 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.
SA-026
SA-2294
Prevent Parts from Flying Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. Do not attempt to remove grease fitting securing cover. 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.
S-27
SA-344
SAFETY 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.
SA-034
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.
SA-039
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.
SA-225
S-28
SAFETY 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.
SA-019
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.
SA-031
SA-292
SA-044
S-29
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. Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance. 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. Never attempt to modify electric wirings.
S-30
SA-019
SAFETY 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 adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval. Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents. Do not store oily cloths as they are vulnerable to catching fire. Keep flammables away from open flames. Do not ignite or crush a pressurized or sealed container. Wire screens may be provided on openings on the engine compartment covers to prevent flammables such as dead leaves from entering. However, flammables which have passed through the wire screen may cause fires. Check and clean the machine every day and immediately remove accumulated flammables. 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. 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. If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as mufflers may cause fire. Always close the engine cover while operating the machine.
S-31
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 to the explanation pages on the Emergency Evacuation Method.
SA-393
SS-1510
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.
SA-016
S-32
SAFETY 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.
S-33
SA-818
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 not 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 fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. SA-030
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.
Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. Strictly comply with the following items: Do not disassemble the unit. Keep the units away from open flames and fire. Do not bore a hole, do not cut by torch. Avoid giving shocks by hitting or rolling the unit. Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer.
S-34
SAFETY 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.
SA-029
Beware of Asbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust or other contamination may cause sickness. Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist. Spray water to prevent asbestos fibers, silicon dust or other contamination from becoming airborne. Do not use compressed air. When operating the machine in a work site where asbestos fibers, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination. Keep bystanders out of the work site during operation. Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.
S-35
SA-029
SAFETY 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. Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.
SA-032
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.
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.
SA-405
S-36
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.
SA-309
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.
S-37
SA-226
SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice.
Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.
S-38
SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment. Any person affixed with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters (8.662 inches) apart at all times. If such condition cannot be met, please contact our company's nearest dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves. Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 0.573 W/Kg (914.80 MHz) DCS-1800 0.130 W/Kg (1710.20 MHz) WCDMA Band I 0.271 W/Kg (1950.00 MHz) *This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.18 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone. In Japan: *Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010). In EU Member nation: *Under the "Council Recommendation 1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg (as of March 2010).
S-39
SA-2302
SAFETY MEMO
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S-40
SAFETY SIGNS 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. ZX470-5 class 18 1
Right Window
4 3
7
8
21 6 2
5
20
10
11 13
Engine Room
19
9
12
Accumulator
Bottom of the Engine (Radiator Side)
14 17
16
15 Bottom of the Radiator
SS-3347
S-41
SAFETY SIGNS ZX870-5 class 18 Right Window
3 4
1 2
8
7 6
5
12
11 9 16
10
17
19
Accumulator
14
SS-3348
S-42
SAFETY SIGNS 1. WARNING! Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator’s Manual.
SS-1616
2. 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.
SS4420333
3. Sign indicates an electrocution hazard if machine is brought too near electric power lines. Keep a safe distance from electric power lines.
SS-1613
4. Sign indicates a hazard form falling window. After raising window, be sure to lock it in place with lock pins.
SS-1618
S-43
SAFETY SIGNS 5. If the machine should overturn, the operator may become injured and/or thrown from the cab and/or crushed by the overturning machine.
SS4654287
6. Do not extend your hands or head from the window. Your hands or head may come in contact with the boom.
SS4459990
7.
SSYA00000341
S-44
SAFETY SIGNS 8. Sign indicates a hazard of being hit by the working device of the machine. Keep away from machine during operation.
SS3092124
9. Sign indicates a hazard of a flying plug from track adjuster that could cause injury. Read manual before adjusting track for safe and proper handling.
SS3086091
10. 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 handling.
A
SS4459928
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.
B
SS4420336
S-45
SAFETY SIGNS 11. Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine.
SS-1614
12.
A
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.
SS4420336
B
SS-710
13. 14. 15. Sign indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.
SS4623852
SSYA00008776
S-46
SAFETY SIGNS 16.
A
Sign indicates an explosion hazard. Keep fire and open flames away from this area.
SS4460067
Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte.
B
SS4460056
17. Sign indicates an electrical hazard from handling the cable. Read manual for safe and proper handling.
SS4459714
S-47
SAFETY SIGNS 18.
SS4467093
19.
SS-1022
20. Sign indicates a hazard of falling off the fender or hood. Never stand close to the edge.
SS3092125
21.
SS4318016
S-48
COMPONENTS NAME Components Name 4
1- Bucket 2- Bucket Cylinder
3
3- Arm 4- Arm Cylinder 5- Boom
5
2
6
6- Hydraulic Oil Tank
7
7- Fuel Tank 14
8- Counterweight 9- Engine
13
1
10- Track 11- Travel Device
12
12- Front Idler 13- Cab 14- Boom Cylinder
8
15- Muffler
fNOTE:
9
The illustration shows ZX850-5 class. 15
11
10 TJBE-01-02-001
1-1
GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Foot holds and handrails are provided in and around the machine. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely. Never jump on or off the machine as it is very dangerous.
dWARNING: Never attach a wire on the foot holds to lift the cab or main body or while transporting the machine on a truck or trailer as it is dangerous. The door knob is not a handrail. Do not use the door knob as a handrail when getting on and off the machine. Do not hold the control levers or control shut-off lever when getting on and off the machine.
M1JB-01-001
M1JB-01-002
1-2
OPERATOR’S STATION Cab Features (Std. Model)
1
2
3
4
5
6 7
1- Left Control Lever/Horn Switch 2- Left Travel Pedal 3- Left Travel Lever 13
4- Right Travel Lever
8
5- Right Travel Pedal 6- Right Control Lever/Power Boost Switch
9
7- Multi Function Monitor Panel 8- Switch Panel
10
9- Key Switch
12
10- Switch Panel (for Optional Equipment)
Glove Compartment (without Optional Equipments)
11- Operator's Seat 12- Cab Door Release Lever 13- Pilot Control Shut-Off Lever
MDAA-01-347
11
14- Glove Compartment 15- Fuse Box 16- Cigar Lighter
14
18
16
17- Switch Panel (for Optional Equipment)
15
Glove Compartment (without Optional Equipment)
18- Glove Compartment (Hot and Cool Box) 19- Engine Stop Switch 17
20- Handle (Emergency Engine Stop)
MDAA-01-289
19
1-3
20
MDCD-01-001
OPERATOR’S STATION Cab Features (with Attachment)
1
2
3
4
5 6 7 8
1- Left Control Lever/Horn Switch 2- Left Travel Pedal 3- Left Travel Lever 14
4- Right Travel Lever
9
5- Right Travel Pedal 6- Attachment Pedal
10
7- Right Control Lever/Power Boost Switch 8- Multi Function Monitor Panel
11
9- Switch Panel
13
10- Key Switch 11- Switch Panel (for Optional Equipment)
Glove Compartment (without Optional Equipments)
12- Operator's Seat 13- Cab Door Release Lever
MDAA-01-348
12
14- Pilot Control Shut-Off Lever 15- Glove Compartment 16- Fuse Box
15
19
17- Cigar Lighter
17
18- Switch Panel (for Optional Equipment)
16
19- Glove Compartment (Hot and Cool Box) 20- Engine Stop Switch 18
21- Handle (Emergency Engine Stop)
MDAA-01-289
20
1-4
21
MDCD-01-001
OPERATOR’S STATION Multi Function Monitor Feature The multi function monitor displays various meters, indicators, radio and air conditioner, ten-key lock function, rearview camera image, work mode selection and maintenance screen. Screen Configuration The multi function monitor consists of the following screens. There are 7 menus, and a further 15 sub menus.
Basic Screen
Main Menu
Alarm List Air Conditioner Radio Work Mode Mail (Optional) Setting Menu
Date and Time Attachment Adjust Attachment Name Input Password Change Sub Meter Selection Rear View Camera Monitor Display Item Selection Brightness Adjustment
Unit Selection Main Menu Sequence Change
Information Menu
Operation Maintenance Troubleshooting Monitoring
1-5
OPERATOR’S STATION Default Setting Function Security
fNOTE:
Item Password Extending Password Duration Time
Default 0000 0 min
Typical functions are shown in the table. Check the initial values of other functions on each monitor screen.
1-6
OPERATOR’S STATION Basic Screen 1
1- Work Mode Display
2
3
4
5
6
2- Auto-Idle Display 3- Power Mode Display
7
4- Auto-Lubrication Display (Optional) 5- Hour Meter, Clock
8
6- Preheat Display
13
7- Seat Belt Display 8- Fuel Gauge
9
9- Sub Meter 12
10- Radio Display 11- Air Conditioner Display 12- Coolant Temperature Gauge 13- Travel Mode Indicator
11
10
MJAC-01-012
1-7
OPERATOR’S STATION 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 ACC or ON position, the starting screen displays for about two seconds. When the key switch is kept in ACC position, only hour meter, clock and radio will be displayed. When the key switch is turned from ACC to ON position, the basic screen will be displayed. Starting Screen
Basic Screen
MDAA-01-003EN
MDAA-01-001EN
IMPORTANT: When the key switch is turned to ON position, the alternator alarm will be displayed on the basic screen. Until the alternator starts generating power after the engine starts, the alternator alarm is displayed on the basic screen. Alternator Alarm
MDAA-01-043EN
1-8
OPERATOR’S STATION Display of Meters Items to be displayed 4- Hour Meter, Clock
Work Mode
4
9- Fuel Gauge 13- Coolant Temperature Gauge
9
Work Mode Display The attachments being used are displayed.
13
Digging Mode
MDAA-01-001EN
Attachment Mode Breaker
Pulverizer
Crusher
Vibrating Hammer
Grapple
Clamshell
Others
1-9
OPERATOR’S STATION Auto-Idle Display (2) When the auto-idle is selected from the switch panel, the auto-idle display (18) displays. When the key switch is turned ON while the auto-idle switch is also ON, the auto-idle display blinks for 10 seconds. Power Mode Display (3) Displays the power mode selected from the switch panel. Auto-Lubrication Display (4) (Optional) Displays when the auto-lubrication switch is turned ON. Preheat Display (6) While the current is being supplied to the glow plug, the indicator is displayed. Seat Belt Display (7) Turns ON when the key switch is in the ON position, and turns OFF 5 seconds after the engine starts. Sub Meter Display (9) Fuel consumption or breaker hour meter is displayed. Radio Display (10) Displays the radio panel Air Conditioner Display (11) Displays the air conditioner panel. Travel Mode Display (13) Displays the travel mode selected from the switch panel.
1-10
1
2
3 4
5 6 7 8
13
9
12
11
10
MJAC-01-013
OPERATOR’S STATION Hour Meter Total (accumulated) machine operation hours counted since the machine started working, are displayed in hours (h). One digit after the decimal point indicates tenths of an hour (6 minutes). MDAA-01-021EN
Clock Indicates the present time. 24-h/12-h display can be selected. (Refer to "Date and Time" for switching the display mode.)
Fuel Gauge The remaining fuel amount is indicated by the needle. Refuel before the needle reaches "E".
MDAA-01-276
1-11
OPERATOR’S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. Normally the needle is around the center of the scale during operation.
M1U1-01-047
Operating Status Icon Display
1
2
Displays icons indicating the current status of the attachment (1) selected from the work mode selection screen; and power mode (3), preheat indicator (4), travel mode (5), and auto-idle (2) ON selected from the switch panel, when these systems are activated.
3
4
MJAC-01-014
5
1-12
OPERATOR’S STATION Security Functions Input Password IMPORTANT: When required to activate the numeric keypad function, consult your nearest Hitachi dealer. If the password is forgotten, the machine must be modified. Be extremely 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
MDAA-01-003EN
Password Input Screen
MDAA-01-085EN
2. Input a password by using the numeric keypad. 3. The monitor unit matches the input password to the registered one. If they match, the basic screen displays. The engine is ready to run. If an incorrect password is input three times, a buzzer sounds for thirty seconds. During that time, the buzzer does not stop even if the key switch is turned ON/OFF.
fNOTE:
If you make a mistake while entering the password, push the CLEAR key in order to erase the entered characters.
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 the password can be input again. 5. If an incorrect password is input again, the buzzer sounds for a further thirty seconds.
MDAA-01-086EN
Basic Screen
1-13
MDAA-01-001EN
OPERATOR’S STATION Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that require a password. By using the password duration screen, password duration time can be set. When restarting the machine, a password need not be input within the specified timeframe. 1. When turning the key switch from ON to ACC position, the monitor unit displays the password duration screen for ten seconds. MDAA-01-087EN
2. While the password duration screen is still displayed, rotate selector knob (1) to highlight the relevant time. Pushing selector knob (1) sets the password duration time. Duration time Duration time Duration time Duration time Duration time
Password Duration Screen (Key Switch: OFF)
1
0 minute 30 minute 60 minute 90 minute 120 minute
fNOTE:
If the password duration time is not set explicitly, a duration of 0 is assumed.
3. If turning the key switch to the ON position within the password duration time, the monitor unit displays the basic screen after the starting screen.
MDAA-01-040
Starting Screen
MDAA-01-003EN
MDAA-01-001EN
1-14
OPERATOR’S STATION Alarm Occurrence Screen In case any abnormality occurs, alarm marks (1) are displayed on the basic screen. If six or more alarms are generated, the alarm marks (1) can be scrolled by rotating switch (2).
1
MDCD-01-021
Indicator
2
MDAA-01-040
1-15
OPERATOR’S STATION Follow the procedure below to display detailed information for an alarm. Push selector knob (1) on the basic screen to display the main menu. Rotate selector knob (1) to select the alarm list, and push selector knob (1). Rotate selector knob (1) to select a required alarm from the alarm list, and push selector knob (1). Detailed information of the selected alarm will be displayed.
MDCD-01-003
1
MDAA-01-040
The main menu displays the alarm list only dCAUTION: when an alarm occurs.
MDAA-01-077EN
The alarm list contains only currently dCAUTION: generated alarms.
MDCD-01-006EN
1-16
MDCD-01-007EN
OPERATOR’S STATION Remedy Display
Contents of Alarms
Remedy
Engine Oil Level Alarm
Check engine oil level and refill oil.
Coolant Level Alarm
Check coolant level and add coolant if necessary.
Overheat Alarm
Engine coolant temperature has abnormally increased. Stop operation. Run the engine at slow idle speed to lower the coolant temperature.
Hydraulic Oil Overheat Alarm
Hydraulic oil temperature is above normal. Stop operation, check hydraulic oil level, check for leaks etc.
Engine Trouble Alarm
Engine or engine related parts are abnormal. Consult your nearest Hitachi dealer.
Engine Oil Pressure Alarm
Engine oil pressure has decreased. Immediately stop the engine. Check the engine oil system and oil level.
Engine Start Disabled
As the pilot shut-off lever is lowered, the engine cannot start.
Engine Start Disabled
As the engine emergency switch is ON, the engine cannot start.
Alternator Alarm
Electrical system is abnormal. Check alternator and battery system.
Fuel Level Alarm
Fuel level is low. Refill fuel as soon as possible.
1-17
OPERATOR’S STATION
Display
fNOTE:
Contents of Alarms
Remedy
Auto-Lubrication Alarm
Auto-Lubrication System is abnormal. Replace grease can and/or check grease supply piping for any failure.
Hydraulic Oil Filter Restriction Alarm
The hydraulic oil filter is clogged. Clean or replace the hydraulic oil filter.
Air Cleaner Restriction Alarm
Air filter elements are clogged. Clean or replace air filter elements.
System Failure Alarm
Communication system is abnormal. Consult your nearest Hitachi dealer.
Pilot Control Shut-Off Lever Alarm
Pilot control shut-off lever system is abnormal. Consult your nearest Hitachi dealer.
The hydraulic oil filter alarm lights only when the high performance element (optional) is used.
1-18
OPERATOR’S STATION Fuel Sensor Error Display If the fuel sensor is faulty, the color of the fuel mark changes and the needle disappears. If the harness between the fuel sensor and the controller unit is broken, the needle disappears.
Coolant Temperature Sensor Error Display
Fuel Sensor Error Display
Coolant Temperature Sensor Error Display If the coolant temperature sensor is faulty, color of the temperature mark changes and the needle disappears. If the harness between the temperature sensor and the controller unit is broken, the needle disappears.
MDAA-01-024EN
1-19
OPERATOR’S STATION Main Menu Press selector knob (2) while displaying basic screen (1) to display main menu screen (3). The main menu screen contains the items shown in the figure to the right. The alarm list is displayed only when an alarm is generated. Mail (optional) menus will not be displayed unless they are set beforehand.
1
MDAA-01-001EN
2
MDAA-01-040
3
MDAA-01-077EN
MDAA-01-190EN
1-20
OPERATOR’S STATION Air Conditioner 1
Most air conditioner functions are operated by using switches (3) and (4), however air vent selection and turning A/C ON and OFF are performed from the air conditioner setting screen in the menu. (Refer to the page 1-90) Circulation Air Mode 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (5). 2. Rotate selector knob (2) to highlight Air Conditioner (6).
MDAA-01-001EN
3. Press selector knob (2) to display Air Conditioner screen (7).
Rotate selector knob (2) to highlight
(8) mark.
2 3
4. Press selector knob (2) to set the circulation mode.
4
5. Press selector knob (2) again to switch the fresh air mode. Air Conditioner ON/OFF 1. Rotate selector knob (2) to highlight A/C (9). 2. Press selector knob (2) to turn the air compressor ON.
MDAA-01-040
3. Press selector knob (2) again to turn the air compressor OFF.
fNOTE:
When the function is ON, the mark "" is displayed in green. When the function is OFF, the mark "" is displayed in gray.
5
6
IMPORTANT: If mark (10) is displayed on the air conditioner display, communication between the air conditioner and the monitor is abnormal. Consult your nearest Hitachi dealer. MDAA-01-089EN
7 8 9
MDAA-01-091EN
10 MDAA-01-226
1-21
OPERATOR’S STATION Radio Most radio functions are operated by using switches (3) and (4), however memory channel setting, seek function, TONE adjustment, and AUTO PRESET are done at the radio screen in the main menu.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (5). 2. Rotate selector knob (2) to highlight Radio (6). 3. Press selector knob (2) to display the radio screen. (Refer to 1-98)
MDAA-01-001EN
IMPORTANT: If mark (7) is displayed on the radio display, communication between the radio and the monitor is abnormal. Consult your nearest Hitachi dealer. Press the numeric keypad of 1 to 8 while the radio is ON, the radio station will switch to memorized channel of 1 to 8. (Refer to 1-80 and 1-98)
2 3 4
MDAA-01-040
5
6
MDAA-01-092EN
7 MDAA-01-227
1-22
OPERATOR’S STATION Work Mode Front attachment is selected in the Work Mode screen under the Work Mode menu in the main menu.
1
Attachment Selection 1. Press selector knob (2) while displaying Basic screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Work Mode (4). 3. Press selector knob (2) to display Work Mode screen (5). 4. Rotate selector knob (2) to highlight the desired front attachment.
MDAA-01-001EN
(In the right example, "Bucket" is highlighted.) 2
5. Press selector knob (2) to enable the changes.
MDAA-01-040
3
4
MDAA-01-100EN
5 6
MJAA-01-009EN
1-23
OPERATOR’S STATION Mail (Optional) IMPORTANT: This function is available only to a machine equipped with a communication terminal. When using the mail function, consult your nearest Hitachi dealer.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Mail (4). 3. Press selector knob (2) to display Mail screen (5). 4. Rotate selector knob (2) to highlight desired request. MDAA-01-001EN
5. Press selector knob (2) to send mail information to the communication terminal.
General Request Fuel Replenishment Request Service Maintenance Request Forwarding Request
2
MDAA-01-040
3
4
MDAA-01-109EN
5
MDAA-01-110EN
1-24
OPERATOR’S STATION 6. While mail information is sent to the communication terminal, the message "Wait." is displayed on the screen.
MDAA-01-111EN
7. When the communication terminal completes receiving mail information, the message "Request Is Accepted." is displayed on the screen.
Push the back key to return to the Mail screen.
8. Then, a mail is sent from the communication terminal to the central server.
fNOTE:
Depending on the machine's operating environment, the mail may not be sent.
fNOTE:
When the communication terminal could not receive the mail, the message "Failed." is displayed on the screen.
MDAA-01-112EN
MDAA-01-113EN
1-25
OPERATOR’S STATION Setting Menu Setting menu consists of date and time setting, attachment adjustment, attachment name, auto shut-down setting, change password, selecting sub meter, brightness adjustment of back monitor and screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-114EN
5
MDCD-01-008EN
1-26
OPERATOR’S STATION Date and Time Time, date and display mode can be set on this screen. Yearmonth-day format and 24h/12h display mode are selected in the display setting.
1
Time Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
MDAA-01-001EN
4. Rotate selector knob (2) to highlight Date and Time (6). 2
MDAA-01-040
3
4
MDAA-01-114EN
5 6
MDCD-01-008EN
1-27
OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight Time Setting (8). 7. Press selector knob (2) to display Time Setting screen (9).
7 8
MDAA-01-117EN
8. Rotate selector knob (2) to highlight Hour or Minute and push selector knob (2). 9. Rotate selector knob (2) to adjust the clock. Rotate clockwise to adjust the number upwards, and counterclockwise to decrease it.
10
10. Push selector knob (2) to end the Time setting procedure. 11. Rotate selector knob (2) to highlight selector knob (2) to make the change.
9
11
(11). Push
MDAA-01-118EN
MDAA-01-121EN
1-28
OPERATOR’S STATION Date Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Date and Time (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-114EN
5 6
MDCD-01-008EN
1-29
OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight Date Setting (8). 7. Press selector knob (2) to display Date Setting screen (9).
7
8
MDAA-01-122EN
8. Rotate selector knob (2) to highlight Year, Month or Day and push selector knob (2). 9. Rotate selector knob (2) to adjust the clock. Rotate clockwise to adjust the number upwards, and counterclockwise to decrease it.
9
10
10. Push selector knob (2) to end the date setting procedure. 11. Rotate selector knob (2) to highlight selector knob (2) to make the change.
(11). Push 11
MDAA-01-123EN
MDAA-01-127EN
1-30
OPERATOR’S STATION Display Mode Setting 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Date and Time (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-114EN
5 6
MDCD-01-008EN
1-31
OPERATOR’S STATION 5. Press selector knob (2) to display Date and Time screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight Display Form (8). 7
8
MDAA-01-228EN
7. Press selector knob (2) to display Display Form screen (9). 8. Rotate selector knob (2) to highlight Date (10) and push selector knob (2). Time : Each time selector knob (2) is pushed, the time format is changed as follows: 12 h 24 h 12 h. Date : Each time selector knob (2) is pushed, the date format is changed as follows: YYYY/MM/DD MM/DD/YYYY DD/MM/YYYY YYYY/MM/DD.
9 10
MDAA-01-229EN
MDAA-01-230EN MDAA-01-231EN MDAA-01-232EN MDAA-01-233EN MDAA-01-234EN
1-32
OPERATOR’S STATION Attachment Adjust The supply flow rate to an attachment can be adjusted on the Attachment Adjust screen. The attachment adjustment can be done when the work mode is set to an attachment other than the bucket. Select an attachment other than the bucket on the work mode screen. (Refer to "Work Mode".)
1
Flow Rate Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MDAA-01-001EN
2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Attachment Adjust (6).
2
MDAA-01-040
3
4
MDAA-01-114EN
5
6
MDCD-01-009EN
1-33
OPERATOR’S STATION 5. Press selector knob (2) to display Attachment Adjust screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight Pump Flow Rate (8). 7 8
MJAA-01-006EN
7. Press selector knob (2) to display Pump Flow Rate screen (9). 8. Rotate selector knob (2) clockwise or counterclockwise to adjust the pump flow rate.
9
MDAA-01-130EN
1-34
OPERATOR’S STATION Attachment Name Input Attachment name can be changed on this screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Attachment Name Input (6). MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-114EN
5
6
MDCD-01-011EN
1-35
OPERATOR’S STATION 5. Press selector knob (2) to display Attachment Name Input screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight desired attachment name (8). 7 8
MJAA-01-010EN
7. Press selector knob (2) to display Name Change screen (9). 8. Rotate selector knob (2) right and left to highlight a character, and push selector knob (2).
9
9. After inputting the new name, rotate selector knob (2) to highlight "SET". Push selector knob (2) to finalize the setting.
fNOTE:
In order to delete the last entered character, turn selector knob (2) to highlight "BS" (Back Space), and then push selector knob (2). In order to delete all entered characters, rotate selector knob (2) to highlight "ALL CLEAR". Push selector knob (2).
MDAA-01-137EN
MDAA-01-145EN
1-36
OPERATOR’S STATION Password Change 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
1-37
OPERATOR’S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 5
4. Rotate selector knob (2) to highlight Password Change (6).
6
MDAA-01-156EN
5. Press selector knob (2) to display Password Change screen (7).
2
MDAA-01-040
7
MDAA-01-157EN
6. Input current password from the numeric keypad.
Current Password
MDAA-01-158EN
1-38
OPERATOR’S STATION 7. Input the new password and push selector knob (2). 3 to 8 digits can be input for password.
MDAA-01-159EN
New Password
MDAA-01-160EN
1-39
OPERATOR’S STATION 8. Input the new password again to confirm it and push selector knob (2).
MDAA-01-161EN
MDAA-01-162EN
2
MDAA-01-040
9. The password has changed.
MDAA-01-163EN
1-40
OPERATOR’S STATION Sub Meter A sub meter selection menu that can be added to the fuel meter is selected on this screen. OFF and Breaker Hour Meter are provided. The breaker hour meter indicates the breaker operation time.
1 Sub Meter
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4). 3. Press selector knob (2) to display Setting Menu screen (5).
MDAA-01-315EN
4. Rotate selector knob (2) to highlight Sub Meter Selection (6). 2
MDAA-01-040
3
4
MDAA-01-114EN
5
6
MDAA-01-164EN
1-41
OPERATOR’S STATION 5. Press selector knob (2) to display Sub Meter Selection screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight desired sub meter (8). (Selecting OFF will not display a sub meter.) 7
7. Press selector knob (2) to enable the changes.
8
f
NOTE: When a display is selected, the mark "" is displayed in green. When not selected, the mark "" is displayed in gray.
MDCD-01-012EN
1-42
OPERATOR’S STATION Rear View Camera Monitor (Optional) IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. Actual position and distance of people and objects in the rear view monitor will be different. When operating the machine, pay thorough attention to the surrounding situation.
1
Rear View Camera ON/OFF 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Setting Menu (4).
MDAA-01-001EN
3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Rear View Camera Monitor (6).
2
MDAA-01-040
3
4
MDAA-01-114EN
5 6
MDAA-01-168EN
1-43
OPERATOR’S STATION 5. Press selector knob (2) to display Rear View Camera Monitor screen (7).
2
MDAA-01-040
6. Press selector knob (2) to turn the rear view camera monitor ON/OFF. 7
7. When the rear view camera monitor is ON, rear view image is continuously displayed on the basic screen. IMPORTANT: In order to obtain a clear image, clean the lens and the monitor display before operating the machine.
fNOTE:
The monitor and camera lens surface is a resin product. Lightly wipe the surface with a wet clean cloth. Never use an organic solvent.
IMPORTANT: Never attempt to change the mounting position of the rear view camera. Consult your authorized dealer if any abnormality is found on the rear view image.
1-44
MDAA-01-169EN
OPERATOR’S STATION Brightness Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
3. Press selector knob (2) to display Setting Menu screen (5). 5
4. Rotate selector knob (2) to highlight Brightness Adjustment (6).
6
MDAA-01-171EN
1-45
OPERATOR’S STATION 5. Press selector knob (2) to display Brightness Adjustment screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) clockwise to make the screen brighter, counterclockwise to make the screen darker.
7
MDAA-01-172EN
fNOTE:
When the light is turned ON, the monitor screen changes to night mode and mark (8) is displayed. Brightness can be adjusted for day mode and night mode respectively. 8
fNOTE:
Even if the light is turned ON during daytime, you can activate the daytime screen by pushing "0" (9) on the numeric keypad.
MDAA-01-173EN
9
MDAA-01-018
1-46
OPERATOR’S STATION Language Settings 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight
(6).
5
6
MDAA-01-176EN
1-47
OPERATOR’S STATION 5. Press selector knob (2) to display (7).
screen 2
MDAA-01-040
6. Rotate selector knob (2) to highlight the desired language. Press selector knob (2) to make the change.
fNOTE:
7
When a display is selected, the mark "" is displayed in green. When not selected, the mark "" is displayed in gray.
MDAA-01-177EN
1-48
OPERATOR’S STATION Lists of Display Language Language
Screen Display
Language
Japanese
Indonesian
English
Thai
Spanish
Vietnamese
Italian
Myanmarese
French
Arabic
German
Persian
Dutch
Turkish
Russian
Danish
Portuguese
Estonian
Finnish
Polish
Greek
Icelandic
Swedish
Croatian
Norwegian
Slovak
Chinese (Simplified)
Romanian
Chinese (Traditional)
Bulgarian
Korean
1-49
Screen Display
OPERATOR’S STATION Unit Selection Unit system displayed on the monitor can be selected in this screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Unit Selection (6).
5
6
MDAA-01-181EN
1-50
OPERATOR’S STATION 5. Press selector knob (2) to display Unit Selection screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight desired unit system. Press selector knob (2) to set the unit (Metric or US system).
7
MDAA-01-182EN
7. Before changing °C and °F, turn the blower of the air conditioner ON.
Rotate selector knob (2) to highlight desired unit system. Press selector knob (2) to set the unit (°C or °F).
When pressing selector knob (2), "Wait." will be displayed and then the change will be completed.
MDAA-01-183EN
MDAA-01-184EN
1-51
OPERATOR’S STATION Display Item Selection (Rear View Camera OFF) The display under the meters can be set to OFF (disable), Logo or Operational information.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
3. Press selector knob (2) to display Setting Menu screen (5). 5
4. Rotate selector knob (2) to highlight Display Item Selection (6).
6
MDCD-01-018EN
1-52
OPERATOR’S STATION 5. Press selector knob (2) to display Display Item Selection screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight desired display (8). Press selector knob (2) to set the image. (Selecting OFF sets non-display.)
7
fNOTE:
When a display is selected, the mark "" is displayed in green. When not selected, the mark "" is displayed in gray.
MDAA-01-238EN
Logo
Operation Information
1-53
MDAA-01-239EN
MDAA-01-222EN
OPERATOR’S STATION Main Menu Sequence Change Menu sequence of Air Conditioner, Radio, Work Mode, and Mail can be changed in this screen. Frequently used menu can be located on top of the screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
MDAA-01-001EN
2
MDAA-01-040
2. Rotate selector knob (2) to highlight Setting Menu (4). 3
4
MDAA-01-114EN
1-54
OPERATOR’S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 5
4. Rotate selector knob (2) to highlight Main Menu Sequence Change (6).
6
MDAA-01-186EN
5. Press selector knob (2) to display Main Menu Sequence Change screen (7).
2
MDAA-01-040
6. Rotate selector knob (2) to highlight a menu to be on the top of the screen. Press selector knob (2) to set the menu to the top of the screen.
7
MDAA-01-187EN
1-55
OPERATOR’S STATION Information Menu The information menu includes Operation, Maintenance, Troubleshooting and Monitoring.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5
MDAA-01-191EN
1-56
OPERATOR’S STATION Operation The Operation screen displays Breaker Operation, Attachment Operation, Travel Operation, and Actual Operation menus. The Breaker Operation screen displays breaker operating hours, machine operating hours and operating rate from resetting the monitoring unit. The Attachment Operation screen displays total operating hours of front attachment, travel and all operation from resetting the monitoring unit.
1
Breaker Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4).
MDAA-01-001EN
2
3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Operation (6).
MDAA-01-040
3
4
MDAA-01-190EN
5 6
MDAA-01-191EN
1-57
OPERATOR’S STATION 5. Press selector knob (2) to display Operation Screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight Breaker Operation (8).
7
7. Press selector knob (2) to display Breaker Operation screen (9).
8
MDCD-01-013EN
Operating Time, Machine Operation Hours and Operation Ratio can be checked in this screen. Pushing selector knob (2) returns to the basic screen. To reset the Operation Time and Machine Operation Hours data, rotate selector knob (2) to highlight CLEAR (10), and then push selector knob (2).
9
10
MDAA-01-197EN
1-58
OPERATOR’S STATION Attachment Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Operation (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5 6
MDAA-01-191EN
1-59
OPERATOR’S STATION 5. Press selector knob (2) to display operation screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight Attachment Operation (8).
7
8
MDCD-01-014EN
7. Press selector knob (2) to display Attachment Operation screen (9). The attachment Operating Time can be checked in this screen. Push selector knob (2) to return the previous screen. To reset the Operating Time data, rotate selector knob (2) to highlight CLEAR (10), and then push selector knob (2).
9
10
MDAA-01-200EN
1-60
OPERATOR’S STATION Travel Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Operation (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5 6
MDAA-01-191EN
1-61
OPERATOR’S STATION 5. Press selector knob (2) to display Operation screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight Travel Operation (8). 7. Press selector knob (2) to display Travel Operation screen (9).
7
8
MDCD-01-015EN
Total Travel Operation Time can be checked in this screen. Push selector knob (2) to return the previous screen. To reset the Operating Time data, rotate selector knob (2) to highlight CLEAR (10), and then push selector knob (2).
9
10
MDAA-01-203EN
1-62
OPERATOR’S STATION Actual Operation 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Operation (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5 6
MDAA-01-191EN
1-63
OPERATOR’S STATION 5. Press selector knob (2) to display Operation screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight Actual Operation (8). 7. Press selector knob (2) to display Actual Operation screen (9).
7
8
MDCD-01-016EN
The actual Operating Time can be checked in this screen. Push selector knob (2) to return the previous screen. To reset the Operating Time data, rotate selector knob (2) to highlight CLEAR (10), and then push selector knob (2).
9
fNOTE:
The Operating Time includes travel operation hours as well as all other operations. 10
MDAA-01-206EN
1-64
OPERATOR’S STATION Maintenance The maintenance screen includes maintenance notice, remaining hours until the next maintenance, and maintenance intervals. Maintenance Items Engine Oil Engine Oil Filter Hydraulic Oil Hydraulic Oil Pilot Filter Hydraulic Oil Full-Flow Filter Pump Transmission Oil (ZX670-5, 870-5 class) Travel Device Oil Swing Device Oil Swing Bearing Grease Air Cleaner Filter Fuel Filter Change Air Conditioner Filter User Setting 1 User Setting 2
1
MDAA-01-001EN
2
Maintenance Notice 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5).
MDAA-01-040
3
4. Rotate selector knob (2) to highlight Maintenance (6).
4
MDAA-01-190EN
5 6
MDAA-01-317EN
1-65
OPERATOR’S STATION 5. Press selector knob (2) to display Maintenance screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight Maintenance Notice (8). 7
7. Press selector knob (2) to turn the Maintenance Notice ON. Press selector knob (2) again to turn the Maintenance Notice OFF. ON : When the required interval is reached, an information message is displayed on the screen. OFF : No notification message is displayed.
8
MDCD-01-023EN
fNOTE:
When the required interval for an item is reached, screen (9) is displayed for 10 seconds when the key is switched ON. Press Return button to delete the notification. When checking the maintenance items from the menu, an item where the set time has been reached are marked with a spanner (10). 9
MDAA-01-213EN
10
MDAA-01-214EN
1-66
OPERATOR’S STATION Time Remains and Maintenance Interval 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Maintenance (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5
6
MDAA-01-223EN
1-67
OPERATOR’S STATION 5. Press selector knob (2) to display Maintenance screen (7). 2
MDAA-01-040
6. Rotate selector knob (2) to highlight a maintenance item to be checked (8). (In the right example, Engine Oil is selected.) 7. Press selector knob (2) to display the time remaining for the selected maintenance item.
Resetting Data To reset the remaining time data, rotate selector knob (2) to highlight RESET (9), and then push selector knob (2). The value of the remaining hours is reset to that of the change interval. The previous change date/hour is updated with the current date and time. Maintenance Interval Setting To change the maintenance interval, rotate selector knob (2) to highlight (11), and then press selector knob (2). The background color of Maintenance Interval (10) changes, then turn selector knob (2) to adjust the time, and then push selector knob (2) to enable the change.
7 8
MDAA-01-336EN
9
MDAA-01-210EN
10 11
MDAA-01-212EN
1-68
OPERATOR’S STATION Troubleshooting A fault code generated by the controller connected to the controller area network is displayed on this screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Troubleshooting (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5
6
MDAA-01-215EN
1-69
OPERATOR’S STATION 5. Press selector knob (2) to start troubleshooting. After displaying "Wait." message, the screen displays controller troubleshooting (7).
2
MDAA-01-040
6. Currently generated fault codes are displayed at the right side of each item. Rotate selector knob (2) to highlight an item displaying the fault codes. 7. Press selector knob (2) to display currently generated fault code (8).
Up to 20 fault codes can be displayed.
IMPORTANT: Send the troubleshooting result to your nearest HITACHI sales representative as soon as possible. MDAA-01-216EN
7
MDAA-01-218EN
8
MDAA-01-219EN
1-70
OPERATOR’S STATION Monitoring Engine speed and PM (particle matter) accumulation in the muffler filter can be checked in this screen.
1
1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). 2. Rotate selector knob (2) to highlight Information Menu (4). 3. Press selector knob (2) to display Information Menu screen (5). 4. Rotate selector knob (2) to highlight Monitoring (6).
MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-190EN
5
6
MDAA-01-220EN
1-71
OPERATOR’S STATION 5. Press selector knob (2) to display Monitoring screen (7). 2
MDAA-01-040
7
MDCD-01-017EN
1-72
OPERATOR’S STATION Switch Panel
1
1- Return to Previous Screen 2- Return to Basic Screen
2 3
3- Selector Knob 4
4- Temperature Control Switch/Mode Switch 5- AUTO/OFF Switch/Fan Switch
6
6- AM/FM Selector/Tuning Switch
5
7- Power Switch/Volume Control Knob
7
8- Engine Control Dial 9- Auto-Idle Switch
8 13
10- Travel Mode Switch 11- Mode Switch
9
12- Work Light Switch
10
13- Wiper/Washer Switch
11
14- Numeric Keypad
12 14
1-73
MDAA-01-310
OPERATOR’S STATION Return to Previous Screen (Monitor) Push this switch to return to the previous screen.
MDAA-01-010
Return to Basic Screen (Monitor) Allows any screen to return to the basic screen.
MDAA-01-011
Select/Confirm Switch (Monitor) Push : Push this switch while the basic screen is displayed, the menu screen opens. Push this switch after the menu screen, the action is confirmed. Rotate : Cursor moves.
MDAA-01-012
Temperature Control Switch/Mode Switch (Air Conditioner) Push : Air vent is selected. Rotate : Setting the temperature.
MDAA-01-013
AUTO/OFF Switch/Fan Switch (Air Conditioner) Push : Push this switch while the air conditioner OFF, it turns AUTO. Push this switch while operating the air conditioner, it turns OFF. Rotate : Adjusting the blower speed. MDAA-01-015
1-74
OPERATOR’S STATION AM/FM Selector/Tuning Switch (Radio) Push : AM/FM is selected. Rotate : Adjusting radio frequency.
MDAA-01-014
Power Switch/Volume Control Knob (Radio) Push : Turns power ON/OFF. Rotate : Adjusting the volume. MDAA-01-016
Engine Control Dial Fast Idle
Use engine control dial (1) to adjust engine speed. The fully clockwise : Fast Idle position Counterclockwise : Slow Idle
1 Slow Idle
M1U1-01-033
1-75
OPERATOR’S STATION Auto-Idle Switch The auto-idle switch (2) sets the engine speed control mode to either Auto-Idle ON or OFF. Auto-Idle Speed When auto-idle selector (2) is turned to ON position, the engine speed decreases to the idle after approximately 4 seconds at the state in which the work lever is turned to neutral. This function saves fuel consumption. When the auto-idle mode is selected, auto-idle indicator (3) on the monitor panel lights.
2
3
MDAA-01-017
MDCD-01-020
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) MBFM-01-003
1-76
OPERATOR’S STATION Mode Switch Three engine speed modes, ECO, PWR, and H/P modes, are selected by operating the mode switch. MDAA-01-274
ECO (Economy) Mode This mode slightly reduces the engine speed according to the operating condition. Digging power is same as the PWR mode. Although production is slightly reduced more than in the PWR mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently. PWR (Power) Mode Operate the machine in this mode when performing normal work. H/P (High Power) Mode Use H/P mode to increase production. The maximum power of the machine can be utilized in this mode, increasing work efficiency when more power is required than in the PWR mode. In the H/P mode, the engine speed changes depending on load applied to the machine. The engine speed increases when boom raise or arm roll-in operations with the engine control dial is in H position. H/P mode increases fuel consumption. To ensure safety, be sure to turn the mode dWARNING: switch to the ECO 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.
1-77
OPERATOR’S STATION Work Light Switch Work light switch has the following positions. 1 Position : Work lights (1) (3) on the right side of the machine and under the cab will light. Also, the switch panel illumination will light. MBFM-01-004
2 Position : Work light (2) mounted on the boom and work light (1) on the right side of the machine and work light (3) under the cab will light. At the same time, the switch panel illumination will light. The monitor changes to night mode. OFF
: Work lights (1), (2), (3) and the switch panel illumination will turn off.
2
fNOTE: When the key switch is turned OFF while the work light switch is in 2-position, the light turns ON for 30 seconds. Work light (3) is equipped only on ZX670-5 and 870-5 class machines.
1
3 MJAA-01-003
1-78
OPERATOR’S STATION Wiper/Washer Switch The wiper and the window washer are operated using the wiper/washer switch.
Middle Slow
Fast
Wiper Turn the wiper/washer switch to the specified position to operate the wiper. OFF Position INT Position
The wiper stops and is retracted. The wiper operates intermittently at the interval selected by the switch position as described below. INT has three positions of operating speed as shown 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.
MBFM-01-005
Wiper
fNOTE:
When the front window (upper) is opened, the wiper and washer will not operate. If the front window is opened while operating the wiper, the wiper stops.
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.
fNOTE:
The wiper motor protection control stops wiper operation to prevent it from becoming immovable when it operates long period of time under high load. When the wiper stops, do not change the arm position and wait several minutes until the wiper starts operation again.
1-79
M1U1-01-018
OPERATOR’S STATION Numeric Keypad Used for inputting password. Press the numeric keypad of 1 to 8 while the radio is ON, the radio station will switch to memorized channel of 1 to 8. When the light is turned ON, the monitor changes to night mode screen. Even if the light is turned ON, you can activate the daytime screen by pushing "0" on the numeric keypad. MDAA-01-018
1-80
OPERATOR’S STATION Switch Panel (for Optional Equipment)
Optional Switch Location
Armrest Adjustment
fNOTE:
The optional switch locations differ depending on the kinds of optional devices are equipped. Before using the switches, make sure what kinds of optional devices are equipped. Raise the armrest when operating the optional switch. All available optional devices are shown below.
Travel Alarm Deactivation Rear Work Light Swing Alarm Auto-Lubrication Auto-Lubrication Selector Boom Mode Seat Heater
MDAA-01-327
Front
Rear Switch Mounting Position Top View
1-81
MJAA-01-004
OPERATOR’S STATION 1
Travel Alarm Deactivation Switch (Optional) (1) The travel alarm buzzer sounds during travel operation. When pushing the mark of travel alarm deactivation switch (1), the travel alarm buzzer function is deactivated.
M1U1-01-035
2
Rear Light Switch (Optional) (2) When rear light switch (2) is turned ON. The rear light at the rear of the cab roof comes ON.
M1U1-01-009
Boom Mode Switch (3)
3
When boom mode switch (3) is turned ON, machine up lifting at digging operation is controlled. This mode controls uplifting of machine at digging operation and reduces machine vibration. Machine can be jacked up by turning OFF the switch when evacuating from mud lake.
M1J1-01-020
IMPORTANT: Turn boom mode switch (3) OFF when operating a breaker attachment. The chisel's strength will weaken if the switch is left ON, becoming unable to apply adequate impact.
4
Swing Alarm Deactivation Switch (Optional) (4) The swing alarm system sounds the buzzer and turns the beacon light ON during swing operation. When pushing the mark of swing alarm deactivation switch (4), the swing alarm buzzer function is deactivated.
M1U1-01-036
1-82
OPERATOR’S STATION Auto-Lubrication Switch (5)
5
When auto-lubrication switch (5) is turned ON, the front attachment is lubricated at specific intervals.
M1J1-01-018
6
Auto-Lubrication Selector Switch (Optional) (6) When auto-lubrication selector switch (10) is set to AUTO, the front attachment is lubricated at specific intervals. When it is set to MANUAL, the front attachment can be lubricated manually by using a grease gun connected to the lubricator. When the switch is turned OFF, the front attachment can not be lubricated.
M1J1-01-032
7
Seat Heater Switch (Optional) (7) When seat heater switch (2) is turned ON, the heater warms the sitting area. When the sitting area reaches specific temperature, the heater stops heating. CAUTION: If you feel abnormal heat, there is a possibility of getting low temperature burn injury. Immediately stop the seat heater and consult your nearest Hitachi dealer.
d
1-83
M1U1-01-011
OPERATOR’S STATION Key Switch
1 2
1- OFF (Engine Off ) 2- ACC (Horn, Radio etc.)
3
3- ON (Engine ON) 4- START (Engine Start)
4
MDAA-01-313
Power Boost Switch Power boost switch (5) is provided on the top of the right control lever. While pressing power boost switch (5), the maximum digging power is boosted within approximately 8 seconds to increase work capacity.
5
MDAA-01-292
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. 6
MDAA-01-293
1-84
OPERATOR’S STATION Cigar Lighter Using Cigar Lighter
1
IMPORTANT: In case the cigar lighter does not pop out automatically 30 seconds after pushing the cigar lighter in, pull out the cigar lighter manually. Then, consult the your nearest Hitachi dealer. 1. Turn key switch (1) to the ACC or ON position.
MDAA-01-313
2. Press and release the lighter knob. 3. The cigar lighter knob will return to the original position when the lighter becomes usable. Pull the cigar lighter out to use.
Cigar Lighter
4. After using the cigar lighter, insert the cigar lighter into the panel until the knob is seated in the original position. Using Cigar Lighter Port as External Power Source Use the cigar lighter 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. Do not supply power to accessories for a long time without running the engine. Failure to do so may discharge the batteries. 1. Pull the lighter knob out. 2. Correctly insert the accessory socket into the cigar lighter 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 the cigar lighter into the port.
1-85
MDAA-01-297
OPERATOR’S STATION Cab Light Switch
1
Push switch (1) on the cab light to turn the cab light ON. ON Position
: The cab light comes and stays ON. (The light does not turn ON while the key OFF.) OFF Position : The light goes OFF. Neutral : The room lamp lights on in conjunction with the opening of cab door. The lamp automatically goes off after 30 seconds. (The light turns ON while the key switch is OFF.)
MDAA-01-305
MDAA-01-318
Installing Fire Extinguisher (Optional) A fire extinguisher can be installed at the left rear corner inside the cab. Consult your nearest HITACHI dealer to install a fire extinguisher.
MDAA-01-319 Fire Extinguisher
1-86
OPERATOR’S STATION Pilot Control Shut-Off Lever
1
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.
dWARNING: Always pull pilot control shut-off lever (1) into the full LOCK position. Unless front control lever lock (1) is fully moved to the LOCK position, the front control lever is not locked, possibly creating a hazardous situation. When leaving the machine, always stop the engine. Then, pull the pilot control shut-off lever up to the LOCK position.
LOCK position
MDAA-01-295
1
Always check to be sure that the pilot control shutoff lever is pulled up to the LOCK position before transporting the machine or leaving the machine at the end of the shift. Confirm that the pilot control shut-off lever is in the LOCK position before starting the engine. The engine will not start in other than the LOCK position.
UNLOCK Position
1-87
MDAA-01-296
OPERATOR’S STATION Handle (Emergency Engine Stop) In case the engine does not stop even if the key switch is turned OFF due to failure of the machine, fully pull handle (3) located at the front-left side of the seat stand to stop the engine. IMPORTANT: Stop the engine by pulling the handle in case of emergency.
fNOTE:
If handle (3) is pulled halfway, the fuel cutoff lever of the governor is pulled, so the engine may not start. Also, even if the engine starts, it may stop unexpectedly. Be sure to return handle (3) to the original position after operating it.
1
3
MDCD-01-002
Engine Stop Switch (for Maintenance) When carrying out engine cranking for air bleeding of hydraulic pump, remove cover (1) located at the front-left side of the seat stand and push switch (2) downward to prevent the engine from starting. After operating switch (2), be sure to return switch (2) back to the upward position and install cover (1) in the original position. 2
1-88
MDCD-01-001
OPERATOR’S STATION Fuse Box
Fuse Box 1
Fuse Box 2
Fuse Box 1 10- CONTROLLER 5A 9- BACKUP 10 A 8- ECF 5A 7- START 5A 6- OPTION2 20 A 5- OPTION1 5A 4- SOLENOID 10 A 3- HEATER 20 A 2- WIPER 10 A 1- LAMP 20 A
20- OPTION3 5A 19- HORN 10 A 18- 17- POWER ON 5A 16- GLOW. R 5A 15- AUXLIALY 10 A 14- MONITOR 5A 13- LIGHTER 10 A 12- RADIO 5A 11- EC MOTOR 10 A
MDAA-01-297
Fuse Box 2 30- AUTO LUB. 10 A 29- LIGHT1 20 A 28- PCV 15 A 27- AUXLIALY3 5A 26- QUICK HITCH 5A 25- IMOBI 5A 24- 12V UNIT 10 A 23- CAB LAMP REAR 10 A 22- CAB LAMP FRONT 10 A 21- SEAT HEATER 10 A
40- SPARE
10
20
9
19
8
18
7
17
6
16
5
15
4
14
3
13
2
12
1
11
39- SPARE 38- SPARE M1GR-01-003
37- SPARE 36- SPARE 35- LUBRICATOR 10 A 34- AUXILIARY2 10 A 33- WARNING LAMP 10 A 32- CAB LAMP FRONT+2 10 A 31- SEAT COMPR. 10 A
30
40
29
39
28
38
27
37
26
36
25
35
24
34
23
33
22
32
21
31
M1GR-01-003
1-89
OPERATOR’S STATION Auto Air Conditioner Features Full Auto-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 rotating the temperature control switch clockwise (32 °C) or counterclockwise (18 °C) 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.
1-90
OPERATOR’S STATION Components Name
1
1- Front Vent 2- Foot Vent 3- Defroster Vent 4- Rear Vent 5- Temperature Control Switch/Mode Switch 6- AUTO/OFF Switch/Fan Switch
fNOTE:
Air flow direction can be changed by controlling the louvers at all air vents except for foot vents (2). In addition, the louvers on front vent (1) and defroster vent (3) can be completely opened and closed by hand.
3
2
MDAA-01-295
4
MDAA-01-289
5 6
MDAA-01-040
1-91
OPERATOR’S STATION Controller Part Name and Function Mode Switch (5) Selects the air vent. The selected air vent is indicated on monitor (7). Air flows out of front vent and the defroster vents.
5 6
Air flows out of the front, rear and the defroster vents. Air flows out of the front, rear, foot and the defroster vents. MDAA-01-040
Foot Vent Mode Each time mode switch (5) is pressed, the vent location can be changed in four stages as illustrated below. AUTO
When switch (6) is selected in AUTO: The air vent location is automatically selected. Temperature Control Switch (5): Sets temperature in the cab. Temperature in the cab can be set from 18.0 to 32.0 °C by rotating temperature control switch (5). Temperature can be set by 0.5 °C increments. The set-temperature is displayed on monitor (7).
7
1-92
MDAA-01-001EN
OPERATOR’S STATION Blower Switch (6) When AUTO indicator (8) is ON, the blower speed is automatically controlled. When AUTO indicator (8) is OFF, the blower speed is controlled in 6 steps. Rotate blower switch (6) clockwise to increase blower speed. Rotate blower switch (6) counterclockwise to decrease blower speed. The monitor (7) indicates the corresponding blower fan speed.
5 6
AUTO/OFF Switch (6) Push AUTO/OFF Switch (6) while the air conditioner OFF, it turns AUTO. Press AUTO/OFF switch (6) while operating the air conditioner, it stops operation.
MDAA-01-040
8
7
1-93
MDAA-01-001EN
OPERATOR’S STATION Cab Heater Operation 1. AUTO switch (6):
According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow-in temperature at the vent, and controls the blower speed.
5 6
2. Temperature Control Switch (5):
Adjust temperature control switch (5) so that "25.0" is indicated on the monitor. Control air temperature inside cab using this switch as necessary.
3. As Necessary: Operate Mode switch (5) to manually select the air vent. Operate blower switch (6) to manually control the blower speed. Operate the air conditioner setting screen on the monitor to maintain the air vent in the fresh air mode or circulation mode. Usually the cab heater turns the dehumidifier function OFF, however, it turns ON by switching the A/C to ON at the air conditioner setting screen.
1-94
MDAA-01-040
OPERATOR’S STATION Cooling Operation 1. AUTO switch (6):
Press AUTO switch (6) to set the air conditioner AUTO mode. According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow-in temperature at the vent, and controls the blower speed.
5 6
2. Temperature Control Switch (5):
Adjust temperature control switch (5) so that "25.0" is indicated on the monitor. Control air temperature inside the cab using this switch as necessary.
MDAA-01-040
3. As Necessary: Operate Mode switch (5) to manually select the air vent. Operate blower switch (6) to manually control the blower speed. Operate the air conditioner setting screen on the monitor to maintain the air vent in the fresh air mode or circulation mode. In case the front window (lower) becomes clouded, manually close the defroster vent (3). (It can be closed manually.) 3
1-95
MDAA-01-295
OPERATOR’S STATION Defroster Operation 1. Press AUTO Switch (6) to blow out temperaturecontrolled air. During cold weather season when starting the engine, the engine coolant temperature and air temperature in the cab are low. The Heater StartOperation Control System controls the blow rate to the minimum (LO) in order to restrict cool air from flowing into the cab.
5 6
2. Adjust temperature control switch (5) so that "25.0" is indicated on the monitor. Set the fresh air circulation mode from air conditioner setting screen on the monitor. 3. Select the front vents using mode switch (5).
or the front and rear vents
MDAA-01-040
1
Control air flow direction by adjusting the louvers at the front vent (1) and the defroster vent (3). Control air temperature in the cab by using temperature control switch (5). If the windowpanes become clouded in rainy season or wanted to eliminate moisture, turn A/C to ON at the air conditioner screen on the monitor. Cool Head/Warm Feet Operation Cool and warm air is simultaneously supplied to the head vents and feet vents respectively. 1. Press blower switch (6) to adjust the blower speed. 2. Press mode switch (5) to display the mark monitor.
on the
Turn A/C ON from the air conditioner setting screen on the monitor.
Control air temperature inside the cab by using temperature control switch (5).
1-96
3
MDAA-01-295
OPERATOR’S STATION Tips for Optimal Air Conditioner Usage Air Conditioner Sensor
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. In this case, ventilate air in the cab first by opening the windows for rapid cooling. After starting the engine, press AUTO switch (6). Set temperature to "18.0" on the monitor by using temperature control switch (5). Turn circulation mode ON from air conditioner setting screen on the monitor. Close the window when the cab cools down to the ambient temperature.
MDAA-01-292
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. IMPORTANT: Do not suddenly increase the engine speed. Failure to do so may damage the compressor. 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.
1-97
OPERATOR’S STATION AM/FM Radio Operation Refrain from listening to the radio in the dCAUTION: cab while operating the machine
3
1 2
Controls on the Radio 1- AM/FM Selector/Tuning Switch
"FM" and "AM" are switched over alternately each time the switch is pressed. Rotate the tuning knob clockwise to increase frequency, counterclockwise to decrease frequency. MDAA-01-040
2- Power Switch/Volume Control Knob
Push: Turns power ON/OFF. Turn the volume control knob clockwise to increase the sound volume. Turn it counterclockwise to decrease the sound volume.
4
Tuning Procedure Manual Tuning Procedure Rotate tuning switch (1) until the desired station is reached. Automatic Search Function 1. Press selector knob (3) while displaying basic screen (4) to display main menu screen (5).
MDAA-01-001EN
2. Rotate selector knob (3) to highlight Radio (6).
Press selector knob (3) to display the radio screen.
Rotate selector knob (3) to highlight seek (8). Push selector knob (3) to go to the next higher frequency station. Press selector knob (3).
Rotate selector knob (3) to highlight seek (7). Push selector knob (3) to go to the next lower frequency station. Press selector knob (3).
5
6
MDAA-01-092EN
7 8
MDAA-01-095EN
1-98
OPERATOR’S STATION Station Presetting Procedure Setting from Monitor 1. Select the desired station. Refer to the "Tuning Procedure" in the previous section.
1
2. Press selector knob (1) while displaying basic screen (2) to display main menu screen (3). Rotate selector knob (1) to highlight radio (4). 3. Press selector knob (1) to display Radio screen (5). 4. Rotate selector knob (1) to highlight a CH to preset a station. (CH1 to CH8) 5. Press and hold selector knob (1) for more than 1 second. The current station is preset to the selected CH. Setting from numeric keypad 1. Select the desired station. Refer to the "Tuning Procedure" in the previous section.
7 MDAA-01-310
2. Press and hold one numeric keypad (1 to 8) for more than 1 second. The current station is preset to the selected number of CH.
2
MDAA-01-001EN
3
4
MDAA-01-092EN
5
MDAA-01-093EN
1-99
OPERATOR’S STATION Station Auto-Presetting Procedure Receivable stations can be automatically sought and preset to the memory. 1. Press selector knob (1) while displaying basic screen (2) to display main menu screen (3).
1
2. Rotate selector knob (1) to highlight Radio (4).
Press selector knob (1) to display Radio screen (5).
3. Rotate selector knob (1) to highlight AUTO PRESET (6). 4. Press selector knob (1) to start AUTO PRESET process. The AUTO PRESET scans reception frequency, allocate sought stations to CH1 to CH8 from sensitive station. AM will be preset to CH1 to 4, FM will be preset to CH5 to 8. Operating the radio during scan stops the AUTO PRESET.
MDAA-01-040
2
MDAA-01-001EN
3
4
MDAA-01-092EN
5
6
MDAA-01-099EN
1-100
OPERATOR’S STATION TONE Control 1. Press selector knob (1) while displaying basic screen (3) to display main menu screen (4).
1 2
2. Rotate selector knob (1) to highlight Radio (5).
Press selector knob (1) to display Radio screen (6).
3. Rotate selector knob (1) to highlight TONE (7). 4. Press selector knob (1) to adjust TONE control. Rotate selector knob (1) clockwise to boost treble. Rotate selector knob (1) counterclockwise to boost bass. Press selector knob (1) to enable the changes.
MDAA-01-040
3
MDAA-01-001EN
4
5
MDAA-01-092EN
6
7
MDAA-01-096EN
1-101
OPERATOR’S STATION Audio Input (Optional) IMPORTANT: This function is available only to a machine equipped with an audio input (optional). Use this function with proper sound volume.
1 2
Audio Input Selection Attach the audio input (optional) device and push AM/FM Switch/Tuning Switch (1) to display AM and FM screen as well as AUX input screen (3). Connecting Audio Device By removing AUX IN Cap (4), the audio input terminal appears. Connect your audio device to the audio input terminal of the machine with your audio cable.
MDAA-01-040
IMPORTANT: Use Φ3.5 mm stereo plug for the connection of audio input terminal. IMPORTANT: Put AUX IN cap (4) when the audio input is not in use. 3
Volume Control of Audio Device Turn the volume down to the minimum beforehand, and then turn volume control knob (2) clockwise to adjust the volume. IMPORTANT: If volume control knob (2) has been set to the maximum, you will hear an overwhelming sound; so set the volume control knob to the minimum first and then turn it clockwise to increase it. Adjust the volume knob on the audio device if the sound is too low even volume control knob (2) is set at top.
MDAA-01-340
4
IMPORTANT: Operate your audio device to play or stop the sound. MDAA-01-341
1-102
OPERATOR’S STATION Cab Door Release Lever
dCAUTION: Open the cab door all the way until it securely locks in the latch on the side of the cab. Do not unlock the cab door when the machine is parked on a slope or while the wind is blowing hard. The cab door may close accidently, possibly resulting in personal injury. When opening or closing the cab door, take extra care not to catch fingers between the base machine and the cab door. 1
To unlock the door, push down on lever (1).
1-103
MDAA-01-320
OPERATOR’S STATION Opening/Closing and Removing Cab Inside Window 1
dWARNING: Open, close or remove the upper-front cab window, overhead window, cab door window or lower-front window only after lowering the front attachment to the ground and pulling up pilot control shut-off lever (1) to the LOCK position. Failure to do so may allow the machine to move unexpectedly if a control lever or pedal is touched with a part of the body by mistake, possibly resulting in personal injury or death. Park the machine on a level and solid ground and stop the engine before opening and closing the upper front window. To open the upper front window, hold the window by hands, hold it until the window is locked. When closing the window, it may accidently fall by its own weight. Hold the window by hands until it is completely closed. Since the window stops before it completely closes, do not operate the machine at the position with the window being stopped. The window is not locked at that position, having the possibility of suddenly dropping.
1-104
MDAA-01-295
OPERATOR’S STATION Opening/Closing Upper Front Window (ZX4705G, 470LC-5G, 870-5G, 870LC-5G) Opening Upper Front Window 1. Press lock release lever (1) at the upper center to release the upper front window lock.
1
2. Holding lock release lever (1) at the upper center and lower handle on the upper front window, pull the upper front window up and back until it securely catches into auto locks (3).
2
3. After confirming that the window securely catches into auto locks (3), slide lock pin (2) into the left bracket boss hole to lock the window in position.
M1U1-01-028 Front Window Close LOCK Position
fNOTE:
When the upper front window is opened, the wiper and washer are inoperable.
Front Window Close UNLOCK Position
dCAUTION: Slowly close the upper front window so that not to catch your fingers.
Upper Front Window Suspended Position
Always secure lock pin (2) in the lock position after the upper front window is opened. 4. To close the upper front window, by following the steps 1 to 3 in the reverse order. The window stops before it completely closes, so close the front window by pushing release lever (1) upward.
MDAA-01-328
Push release lever (1) downward to release auto lock (3).
fNOTE:
Unless the upper front window is securely closed, the wiper and washer will not operate. 2
3
1-105
MDAA-01-306
OPERATOR’S STATION Removing and Storing Lower Front Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G) Take care not to pinch yours fingers when dCAUTION: handling the lower front window. Removing and Storing Lower Front Window 1. Open the upper front window beforehand when removing the lower front window. 2. While pulling the lower front window 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 (4). Then, push fastener (1) to lock.
MDAA-01-298
4
1
3
2
3
MDAA-01-299
1-106
OPERATOR’S STATION Opening Side Windows
1
Hold handle (1) and slide rear pane to open the side window.
Side Window
1-107
M178-01-061
OPERATOR’S STATION Opening/Closing Overhead Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)
1
Move lock levers (1) toward center of window. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3). Hold handle (2) and pull window down until "click" sound is heard from left and right locks (1). Note that the overhead window can be used as an emergency exit.
2
MDAA-01-302
3
MDAA-01-303
1-108
OPERATOR’S STATION Opening/Closing Overhead Window (Clear Hatch: If Equipped)
1
Move lock levers (1) toward center of window. Hold handle (2) and lift window until it rises upright. With the window positioned upright, it will be secured in position by dampers (3). Hold handle (2) and pull window down until "click" sound is heard from left and right 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.
2
MDAA-01-302
3
MDAA-01-303
1-109
OPERATOR’S STATION Emergency Exit
1
Escape from the cab in emergency in the following methods: The danger of downfall is always present dCAUTION: when escaping from the cab in emergency, possibly
resulting in serious personal injury. Escape from the cab as safely as possible, depending on the posture of machine and the outside situation.
1. Open the cab door. Escape through the door. 2. If the cab door should be difficult to open or use, open the upper front window. Escape through the window.
fNOTE:
MDAA-01-321
Emergency exit decals (2) are affixed to the front and rear windows. See page "OPENING UPPER FRONT WINDOW" for the opening method of the upper front window.
If decal (3) is affixed to the front window dCAUTION: glass, the glass can be broken. However if decal (3) is
not affixed to the front window glass, the glass cannot be broken with emergency evacuation hammer (1). Take care not to be injured with pieces of broken glass.
3. If upper front window should be difficult to open, check the decal (3) affixed to the window glass.
If decal (3) is affixed to the front window glass, break the front window glass using the emergency evacuation tool (1) installed the cab left side. Then escape through the broken window.
3
2
M1U4-01-012
3
2
4. If decal (3) is not affixed to the front window glass, or if the front window is not available for escaping, break the rear window glass using the emergency evacuation tool (1). Then escape through the broken window. 5. If neither of front and rear windows is available for emergency exit, open the overhead window to escape from the cab.
MDAA-01-322
1-110
OPERATOR’S STATION Adjusting the Seat Adjust the seat only after lowering the dWARNING: front attachment on the ground and 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 or pedal is touched with a part of the body by mistake, possibly resulting in personal injury or death.
1
6
Backrest Adjustment Pull up lever (1) to release backrest lock. Move backrest to the desired position. Move backrest to the desired position and release lever (1).
5
2
7
Seat Fore-Aft Adjustment
7
Pull lever (2) to slide the seat. Seat fore-aft adjustment range is 190 mm with steps every 10 mm. Release the lever at any position, and check that the backrest is locked. 4
3
MJAA-01-015
Weight Adjustment Adjust the weight support to protect operator's body. Rotate lever (3) (scale unit: 10 kg) to adjust the weight support to the operator's weight. Adjustable Range: 50 kg to 130 kg
Height Adjustment Lift both side bottom (7) of the entire seat to the desired height using your entire body force. After a click (locking) sound is heard, slowly release the seat. After the seat is lifted to the highest position beyond the adjustable range, it is possible to lower the seat to the lowest position. The seat height can be set in 4 steps in the 80 mm range between the highest and lowest positions.
1-111
M4GB-01-101
OPERATOR’S STATION Console and Seat Fore-Aft Adjustment
1
6
Operate console slide lever (4) to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers. Seat and console fore-aft adjustment range is 160 mm with steps every 20 mm.
5
2
4
MJAA-01-015
3
Seat Depth Adjustment The fore/after position of only the seat surface can be changed. While pulling up lever (5) provided in the front the seat, slide the seat in the front or rear direction to adjust the seat depth up to 60 mm by 15 mm interval.
5
M4GB-01-094
Inclination Adjustment The inclination of the seat surface can be changed. While pulling up lever (6) provided in the front of the seat, press or release the seat surface to adjust the inclination of the seat surface from 3° to 11° in 4 steps. A : 3° B : 2.5 °
6
M4GB-01-093
Armrest Adjustment Armrest (8) can be pulled upright by hand 100°. Pull the armrest upward when getting on and off the machine. The angle of armrest (8) can be adjusted to the desired position by turning adjusting dial (9) located on the bottom of armrest (8).
8 9
M1G6-01-017
1-112
OPERATOR’S STATION Adjusting Operator's Seat (Air Suspension Type) (Optional) Adjust the seat only after lowering the dWARNING: front attachment on the ground and 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 or pedal is touched with a part of the body by mistake, possibly resulting in personal injury or death.
Adjusting Seat Height
8
IMPORTANT: The seat is an air suspension type.
7
6
Pull lever (1) upward to fill air and raise the seat. Push lever (1) downward to release air and lower the seat. When the seat is properly adjusted for your weight, indicator (2) is in the green zone.
4 5
4
Console and Seat Fore-Aft Adjustment Operate console and seat slide lever (3) to adjust the seat and both right and left consoles to desired distance from the travel pedals and levers. Seat and console fore-aft adjustment range is 160 mm (4.7 in) with steps every 20 mm (0.8 in). Seat Fore-Aft Adjustment Operate seat slide lever (4) to adjust the seat to desired distance from the travel pedals and levers. Seat fore-aft adjustment range is 190 mm with steps every 10 mm. Suspension Adjustment Rotate knob (5) to adjust the suspension. Rotate knob (5) clockwise to decrease suspension stiffness. Rotate knob (5) counterclockwise to increase suspension stiffness.
1-113
3
1
2
MDAA-01-333
OPERATOR’S STATION Seat Depth Adjustment 6
The fore/after position of only the seat surface can be changed. While pulling up lever (6) provided in the front the seat, slide the seat in the front or rear direction to adjust the seat depth up to 60 mm by 15 mm interval.
M4GB-01-094
Inclination Adjustment The inclination of the seat surface can be changed. While pulling up lever (7) provided in the front of the seat, press or release the seat surface to adjust the inclination of the seat surface from 3 ° to 11 ° in 4 steps. A : 3° B : 2.5 °
7
M4GB-01-093
Backrest Adjustment
8
Pull up lever (8) to release backrest lock. Move backrest to the desired position. Move backrest to the desired position and release lever (8).
MDAA-01-333
Armrest Adjustment Armrest (9) can be pulled upright by hand 100°. Pull the armrest upward when getting on and off the machine. The angle of armrest (9) can be adjusted to the desired position by turning adjusting dial (10) located on the bottom of armrest (9).
9 10
M1G6-01-017
1-114
OPERATOR’S STATION Installation and Adjustment of Mirrors Adjust the mirrors before operating the dWARNING: machine. Improper adjustment of the mirrors provides poor visibility, which may cause serious human injury or death.
IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. When operating the machine, pay thorough attention to the surrounding situation. Adjust the mirrors so that persons standing within 1 m from the machine (or object with height of 1.5 m and 30 cm in diameter) can be recognized from the operator's seat. 1 m-Vicinity Visibility The right illustration indicates the visibility from the operator's seat at 1.5 m high from the ground and 1 m apart from the outer edge of the machine. The hatched areas shown in the illustration are interrupted from visibility by the section of the machine equipped with the side and rear view mirrors.
1m
1m
MJAA-01-016
1-115
OPERATOR’S STATION Seat Belt 2
d
WARNING:
1
Be sure to use seat belt (1) when operating the machine. Before operating the machine, be sure to examine seat belt (1) and attaching hardware for any failure. If any damage and/or wear are found, replace the part concerned. Replace seat belt (1) every 3 years regardless of appearance. Seat Belt
M1U1-01-031
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
1
2. Push button (3) on buckle (2) to unfasten seat belt (1). Replace the seat belt if they are damage or worn, or if the seat belt had external damaged such as an accident.
3 M1U1-01-032
1-116
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 (ECO) 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 10 Hours or Daily 1. Perform 10-hour or daily service. (See Maintenance guide -- 10 hours.) 2. Watch for fluid leaks. 3. Lubricate working tool pivots every 10 hours for the first 50 hours, and every 10 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 MEMO
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2-2
OPERATING THE ENGINE Inspect Machine Daily Before Starting Perform the required daily check before starting the engine. Refer to "Maintenance" section for detailed information.
Engine
3. Oil and water leaks, damage to hoses and pipe lines 4. Clogging and damage to radiator, oil cooler and intercooler
Check Points 1. Sag, wear and break of crawler 2. Oil leaks and wear on upper/lower rollers and front idlers 3. Oil leaks from travel devices 4. Looseness and missing of mounting bolts and nuts 1. Check cylinders, pipe lines and hoses for oil leaks and damages. 2. Wear and damage of the bucket 3. Check bucket teeth for looseness, wear and missing 4. Lubrication state of the working device 5. Check for pin anti-extraction pins, stoppers, rings and bolts for damage
6. Looseness and missing of mounting bolts and nuts
Others
7. Washer Fluid
Working Device
Upperstructure
5. Looseness and missing of mounting bolts and nuts 1. Fuel level, leaks and contamination of fuel in tank 2. Hydraulic oil level, leaks and contamination of hydraulic oil tank 3. Movement, play and operating force of all control levers 4. Operation of all hydraulic components, oil leaks and damage to pipe lines and hoses 5. Deformation, break and abnormal noise of upper structure 6. Looseness and missing of mounting bolts and nuts
Undercarriage
Check Points 1. Level and contamination of engine oil and coolant 2. Starting easiness, exhaust gas color, and noise
3-1
1. Operation of instruments, switches, lights and buzzer/ horn 2. Function of parking brake 3. Deformation and break of head guard 4. Abnormal outside appearance of machine 5. Wear and damage of the seat belt
OPERATING THE ENGINE Before Starting Engine
1
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. Insert key switch (2). Turn it to ON position. Press and hold switch (3) with the engine stopped.
The engine oil indicator (4) and coolant level (5) must be displayed in green.
4. Adjust the seat to allow full pedal and control levers stroke with operator's back against the backrest. Fasten the seat belt.
fNOTE:
The monitor surface is a resin product. When the surface becomes dusty, lightly wipe the surface with a wet cloth. Never use an organic solvent. IMPORTANT: The monitor equipped on this machine does not perfectly assure the condition of the machine. Do not rely only on the monitor display for checking the machine conditions; visually check them yourself periodically such as oil level. Refer to the Maintenance section.
MDAA-01-295
LOCK position
2
MDAA-01-313
3
MDAA-01-040
4
5
MJAC-03-001
3-2
OPERATING THE ENGINE Starting the Engine
1
Starting the Engine in Ordinary Temperature 1. If your machine is equipped with the battery disconnect switch, check that the switch is in the ON position. 2. Confirm that pilot control shut-off lever (1) is in the LOCK position. 3. Turn engine control dial (3) to the slow idle position. 4. Sound horn to alert bystanders 5. Insert key switch (2). Turn it to ON position. 6. "Wait-screen (nothing is displayed)" is displayed on the monitor for 2 seconds. Regardless of pilot control shutoff lever (1) position, the engine can not be cranked during this moment. 7. 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 numeric keypad function (ignition block system), consult your nearest Hitachi dealer.
LOCK Position
2
Slow Idle
MDAA-01-313
3
Password Input Screen
3-3
MDAA-01-295
M1U1-01-033
MDAA-01-085EN
OPERATING THE ENGINE
fNOTE:
When the key switch is turned ON, the maintenance notification (4) for the item whose maintenance interval has expired displays for ten seconds. Press Return switch (5) or turn the pilot shut-off lever to UNLOCK position while the rear view camera is enable to delete the notification. 4
8. The basic screen will be displayed on the monitor. Check that the preheat indicator (6) is OFF at this time. 9. Turn key switch (2) to START position to rotate the starter. The engine will start. IMPORTANT: Never operate the starter 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. Failure to do so may cause damage to the starter and/or discharging the batteries.
MDAA-01-213EN
5
10. Release key switch (2) immediately after the engine has started. Key switch (2) will automatically return to ON position.
fNOTE:
White smoke may occur for several minutes after the engine start, this is not a malfunction.
MDAA-01-040
6
Basic Screen
3-4
MDAA-01-042EN
OPERATING THE ENGINE Starting in Cold Weather
1
Preheating 1. Confirm that pilot control shut-off lever (1) is in the LOCK position. 2. Turn engine control dial (3) to around the middle between the L and H position. 3. Sound the horn to alert bystanders. 4. Insert key switch (2). Turn it to ON position. 5. "Wait-screen (nothing is displayed)" is displayed on the monitor for 2 seconds. Regardless of pilot control shutoff lever (1) position, the engine can not be cranked during this moment. 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.
LOCK position
MDAA-01-295
2
IMPORTANT: When required to activate the numeric keypad function (ignition block system), consult your nearest Hitachi dealer. Slow Idle
MDAA-01-313
3
Password Input Screen
3-5
M1U1-03-003
MDAA-01-085EN
OPERATING THE ENGINE
fNOTE:
When the key switch is turned ON, the maintenance notification (4) for the item whose maintenance interval has expired displays for ten seconds. Press Return switch (5) or turn the pilot shut-off lever to UNLOCK position while the rear view camera is enable to delete the notification. 4
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 (6) is lit for automatically.
fNOTE:
In case, preheat indicator (6) does not come ON, preheating is not required. Follow the "Starting the Engine in Ordinary Temperature" section.
MDAA-01-213EN
5
8. As soon as preheat indicator (6) goes OFF, turn key switch (2) to START position to rotate the starter. IMPORTANT: Never operate the starter 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. Failure to do so may cause damage to the starter and/or discharging the batteries. 9. Release key switch (2) immediately after the engine has started. Key switch (2) will automatically return to ON position.
fNOTE:
MDAA-01-040
White smoke may occur for several minutes after the engine start, this is not a malfunction. 6
Basic Screen
3-6
MDAA-01-042EN
OPERATING THE ENGINE Check Instruments After Starting Checking instruments through monitor functions After starting the engine, check the following points through the monitor functions.
1
1. Check that discharge warning indicator (1) is OFF. In case discharge warning indicator (1) stays ON, immediately stop the engine. Inspect the alternator and battery system for any abnormality.
2
2. Check that low engine oil pressure indicator (2) is OFF and the alarm buzzer does not sound.
In case low engine oil pressure indicator (2) stays ON and the buzzer sounds, immediately stop the engine. Inspect the engine oil pressure system and the oil level.
IMPORTANT: In case any abnormality is found on the monitor unit, immediately stop the engine. Inspect the cause of the trouble.
Check engine noise and exhaust gas color: Check that the engine noise and exhaust gas color is normal. NOTE: Check the exhaust gas color as follows. (After warmup operation, run the engine with no loads.) Clear : Normal (Perfect combustion) Black : Abnormal (Incomplete combustion) White : Abnormal (Blowing-by)
f
fNOTE:
White smoke may occur for several minutes after the engine start, this is not a malfunction.
3-7
MJAC-03-002
OPERATING THE ENGINE Using Booster Batteries IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Use only 24 volt booster batteries with sufficient capacity.
d WARNING: An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area. Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.
SA-032
Park the machine and a machine with the booster batteries on a dry 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. 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.
1
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, sparks may fly. Be sure to connect the cable end as far away from the machine batteries as possible. 4. After securely connecting the booster cables, start the engine of the machine on which booster batteries are mounted. 5. Start the engine of the troubling machine.
(Red)
Booster Batteries
3-8
Machine Batteries (Black)
2
6. After the engine starts, disconnect cables (2) and (1), following the procedure below.
Connect First
To Upperstructure Frame of the Machine
Connecting the booster batteries
M104-03-002
OPERATING THE ENGINE Disconnecting the booster cables
1
1. Disconnect black negative (-) cable (2) from the machine frame first.
(Red)
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.
Booster Batteries
Machine Batteries (Black)
2
To Upperstructure Frame of the Machine Disconnect Booster Cable from Frame First
Disconnecting the booster cables
3-9
M104-03-002
OPERATING THE ENGINE Stopping the Engine Engine stop procedure 1. Except for special cases, before stopping the engine, lower the bucket to the ground. 2. Pull pilot control shut-off lever (3) to LOCK position. 3. Turn engine control dial (1) to the slow idle position and run the engine for 5 minutes to cool the engine.
SA-390
3
IMPORTANT: If the engine equipped with a turbocharger is stopped without first performing the cool down operation, the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present inside the turbocharger, possibly causing damage to the turbocharger. 4. Turn key switch (2) OFF to stop the engine.
MDAA-01-295
1 Slow Idle
M1U1-01-033
2
MDAA-01-313
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 the engine speed to lessen possibility of undercarriage damage.
f NOTE: An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction.
4-1
Arrow-mark
M178-03-001
DRIVING THE MACHINE Steering the Machine Using Pedals WARNING: In the standard travel position, the front didlers are positioned at the front of the machine and
Front Idler
Cab
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.
f NOTE: For long-term traveling, push down on pedal tabs (D) and rest feet on the footrests.
Travel Motor M104-01-038
A A
D C B
D C
B
M104-04-009
M104-04-003
M104-04-010
M104-04-005
Forward and Reverse
Pivot Turn
M104-04-011
Spin Turn
4-2
M104-04-007
DRIVING THE MACHINE Steering the Machine Using Levers WARNING: In the standard travel position, the front didlers are positioned at the front of the machine and
Front Idler
Cab
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.
f NOTE: For long-term traveling, push down on pedal tabs (D)
Travel Motor M104-01-038
A
A C
C B
B
D
D
and rest feet on the footrests.
M104-04-009
M104-04-003
M104-04-010
M104-04-005
Forward and Reverse
Pivot Turn
M104-04-011
Spin Turn
4-3
M104-04-007
DRIVING THE MACHINE Travel Mode Switch WARNING: Tipping-over accidents can cause serious dpersonal injury. Do not change travel mode switch (1) while traveling; especially, changing to fast mode (2) when descending slopes will create a very dangerous situation. Always stop the machine before changing the travel speed mode.
3
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 position. Slow Mode: Turn travel mode switch (1) to position. Mark (Fast Speed Mode)
2 1
mark (2) mark (3)
MDAA-01-040
Mark (Slow Speed Mode)
Travel Alarm (Optional) During travel operation, the travel alarm sounds to warn the people near the machine that the machine is traveling. Deactivating Travel Alarm More than 12 seconds after starting to travel the machine, raise the armrest and push the travel alarm deactivation switch to stop the travel alarm. (Within 12 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 once more.
f 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.
4-4
Optional Switch
MJAA-01-008
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 Distance” section on page 4-7.)
4-5
M104-05-012
DRIVING THE MACHINE Raise One Track Using Boom and Arm Keep the angle between boom and arm d90WARNING: to 110 ° and position the bucket’s round side on the
90 to 110 ˚
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. 90 to 110 ˚
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. (The hoe bucket can not be installed in reverse depending on the machine specification.)
M104-05-013
WRONG
SA-817
4-6
DRIVING THE MACHINE Towing Machine a Short Distance
RIGHT
Soft Protector
CAUTION: Cables, straps, or ropes can break causing dserious 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.
Shackle
When your machine becomes struck but the engine is still operational, attach wire ropes to the machine 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.
Wire Rope M104-05-010
WRONG
Shackle hole for towing lightweight objects.
d CAUTION: Check that the travel mode switch is in Turn the auto-idle switch OFF.
Shackle
Select the slow travel mode. Slowly drive the machine when towing.
M104-05-011
Never apply impact loads to the towing cables. Never allow any person to enter between machines when towing. IMPORTANT: Use a shackle for towing the machine. Keep the tow line horizontal, straight, and parallel to the tracks. To prevent the wire ropes from being damaged, place some protective material between the track frame and the wire ropes. Maximum tractive effort ZX470-5 class
329 kN (32500 kgf )
ZX870-5 class
560 kN (57120 kgf )
Wire Rope
position.
4-7
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.
A
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 L (4.2 to 4.8 US gal) Lubricate swing bearing. (See Maintenance Guide, 500 hours)
4-8
M104-05-009
Model
A
ZX470-5 Class
1050 mm (41 in)
ZX870-5 Class
1500 mm (59 in)
DRIVING THE MACHINE Parking the Machine on Slopes WARNING: Avoid parking machine on slopes. The dmachine 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 pilot control shut-off lever (2) to the LOCK position. Block both tracks.
M104-05-014
Parking the Machine 1. Park the machine on a level surface.
1
2. Lower the bucket to the ground.
Slow Idle
3. Turn the auto-idle switch off. IMPORTANT: Turbocharger may be damaged if the engine is not properly shut down.
M1U1-01-033
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.
2
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. Lock Position
8. Lock all access doors and compartments.
4-9
M1U1-01-025
DRIVING THE MACHINE MEMO
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4-10
OPERATING THE MACHINE Control Lever (ISO Pattern)
dWARNING: 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. Never remove the window sash bar.
1
4
Make sure you know the location and function of each control before operating.
5
3
7
8
2
Do not change the control lever operation pattern. Failure to do so may result in operation mistake of the machine.
6
A label showing the control patterns of the levers and pedals is attached on the right side in the cab. When a lever is released, it will automatically return to neutral, and that machine function will stop. 1- Arm Roll-Out MDAA-01-343
2- Arm Roll-In 3- Swing Right 4- Swing Left 5- Boom Lower 6- Boom Raise
3
1
7- Bucket Roll-In
4
8- Bucket Roll-Out 2
6
8
7
5
M104-05-002
5-1
OPERATING THE MACHINE Control Lever (HITACHI Pattern) (Optional)
dWARNING: 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.
1
Never remove the window sash bar.
4
5
3
Make sure you know the location and function of each control before operating.
7
8
2
6
A label showing the control patterns of the levers and pedals is attached on the right side in the cab. 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 MDAA-01-343
4- Arm Roll-Out 5- Boom Lower 6- Boom Raise 7- Bucket Roll-In
1
4
8- Bucket Roll-Out
2 3
M104-05-001
6
8
7
5
M104-05-002
5-2
OPERATING THE MACHINE Attachment Pedal (Hydraulic Breaker) (Optional)
1
The breaker can be operated using attachment pedal (1) located on the right front of the seat, as illustrated. Be sure to lock attachment pedal (1) with dCAUTION: pedal lock (2) when the attachment pedal is not in
use. Do not allow your foot to rest on the pedal when the attachment pedal (1) is not in use. When changing pedal lock (2) position, pull the pilot control shut-off lever up to the LOCK position. MDAA-05-007
IMPORTANT: Turn boom mode switch (5) OFF when operating a breaker attachment. The chisel's strength will weaken if the switch is left ON, becoming unable to apply adequate impact.
5
1. Select the hydraulic breaker icon on monitor work mode selection screen (3). Refer to the descriptions about the work mode on page 5-10 for work mode setting procedures.
M1J1-01-020
3
2. Move pedal lock (2) forward to the UNLOCK position. 3. Push down on attachment pedal (1) to operate the breaker.
Loosen stopper bolt (4) until stopper bolt (4) comes in contact with the bracket in attachment pedal (1) neutral to prevent attachment pedal (1) from being stepped backward.
4. Remove foot from attachment pedal (1) to stop the breaker.
MJAA-01-009EN
5. Always keep attachment pedal (1) locked with pedal lock (2) when attachment pedal (1) is not in use.
Unlocked Attachment Pedal Locked Attachment Pedal
1 2
4 MJAA-05-004
5-3
OPERATING THE MACHINE Attachment Pedal (Hydraulic Crusher) (Optional)
1
The crusher can be operated using attachment pedal (1) located on the right front of the seat, as illustrated. Be sure to lock attachment pedal (1) with dCAUTION: pedal lock (2) when the attachment pedal is not in
use. Do not allow your foot to rest on the pedal when the attachment pedal (1) is not in use. When changing pedal lock (2) position, pull the pilot control shut-off lever up to the LOCK position. MDAA-05-007
1. Select the proper hydraulic breaker mode on work mode screen (3) depending on the necessary oil flow rate of hydraulic crusher employed. 2. Move pedal lock (2) forward to the UNLOCK position.
3
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.
fNOTE:
Up to 11 attachment modes can be registered. Consult your nearest Hitachi dealer for adding or changing the designation of the attachment modes.
MJAA-01-009EN
Unlocked Attachment pedal (Crusher) Locked Attachment pedal (Crusher)
1 2
Fully Tighten the Stopper Bolt MJAA-05-005
5-4
OPERATING THE MACHINE Pilot Control Shut-Off Lever
1
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. Always pull pilot control shut-off lever dWARNING: (1) into the full LOCK position. Unless front control
lever lock (1) is fully moved to the LOCK position, the front control lever is not locked, possibly creating a hazardous situation. When leaving the machine, always 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 shut-off lever is pulled up to the LOCK position before transporting the machine or leaving the machine at the end of the shift.
LOCK position
MDAA-01-295
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.
1
Before Starting Operation: Confirm that pilot control shut-off lever (1) is pulled up to the LOCK position before starting the engine. The engine will not start in other than the LOCK position. Slowly push down control shut-off lever (1) to UNLOCK position before starting operation. Confirm that all control levers and pedals are in neutral and that no part of the machine is in motion. If any part of the machine (any actuator) dWARNING: moves when pilot control shut-off lever (1) is lowered to the UNLOCK position despite the fact that all controls are placed in neutral, the machine is malfunctioning. Immediately pull pilot control shutoff lever (1) back to the LOCK position, and stop the engine. Then, see your authorized dealer.
5-5
UNLOCK Position
MDAA-01-296
OPERATING THE MACHINE Warming Up Operation In cold weather, warm up the machine until coolant and hydraulic oil temperature increases to the appropriate operating temperature.
1
IMPORTANT: The appropriate hydraulic oil operating temperature on this machine is 50 to 80°C. Hydraulic components may be seriously damaged if the machine is operated with low temperature hydraulic oil. In case warming up the machine by relieving the hydraulic system, continuously relieve the relief valve for 10 to 15 seconds while taking a pause for 5 to 10 seconds.
Slow Idle
M1U1-01-033
1. Turn engine control dial (1) to the slow idle position.
(Do not operate the machine until the needle of coolant temperature gauge (2) starts swinging.)
2. After the needle of coolant temperature gauge (2) starts swinging, turn engine control dial (1) to approx. medium position.
2
3. Operate the boom, arm and bucket cylinders slowly to each stroke end several times. 4. Operate the travel and swing functions slowly to allow hydraulic oil to circulate through the systems.
MDAA-01-001EN
5. Warming up operation ends after the above operation is completed.
M1U1-03-006
5-6
OPERATING THE MACHINE Engine Speed Control Increase and decrease the engine speed using engine control dial (1) located on the switch panel, as illustrated. Turn engine control dial (1) clockwise to increase the engine speed. Turn engine control dial (1) counterclockwise to decrease the engine speed.
1
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. MDAA-01-040
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 the key switch to OFF position to stop the engine.
Fast Idle
1 Slow Idle
M1U1-01-033
5-7
OPERATING THE MACHINE Auto-Idle
1
Auto-Idle Function 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 (2) setting when auto-idle selector (3) is 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 dmovement. Be sure to turn auto-idle selector (3) to the
A/I OFF position when unexpected machine movement is undesirable, especially when loading/unloading the machine for transportation.
5-8
MDCD-01-020
2 3
MDAA-01-040
OPERATING THE MACHINE Auto-Idle ON/OFF
1
Note that auto-idle function can be turned ON or OFF by using auto-idle selector (3) 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 Indicator (1) ON
: Auto-Idle Function ON
Auto-Idle Indicator (1) OFF
: Auto-Idle Function OFF
When auto-idle selector (3) is turned OFF with auto-idle indicator (1) ON, indicator (1) will go OFF and the auto-idle system is deactivated.
MDCD-01-020
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 10 seconds and stay ON later. 3
MDAA-01-040
5-9
OPERATING THE MACHINE Work Mode
1
Select Work Mode in the main menu, and choose the appropriate hydraulic circuit and pump flow rate for the front attachment at Work Mode screen.
2
When the engine is started, the digging mode is automatically set. Following four work modes can be selected from the Work Mode screen.
Digging Mode Breaker 1 Mode Breaker 2 Mode Breaker 3 Mode
MDAA-01-001EN
5-10
OPERATING THE MACHINE 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. Work Mode
Description
Digging Mode
Select this mode when using bucket.
Breaker 1 to 3 mode (ZX470 class) Breaker 1 to 4 mode (ZX870 class)
Select this mode when using breaker.
f NOTE: Five work modes shown above are designated as the
standard specifications. Up to 11 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.
1 2
MDAA-01-001EN
5-11
OPERATING THE MACHINE Attachment selection 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
1
2. Rotate selector knob (2) to highlight Work Mode (4). 3. Press selector knob (2) to display Work Mode screen (5). 4. Rotate selector knob (2) to highlight the desired front attachment.
(In the example on the right, "Bucket" (6) is highlighted.)
5. Press selector knob (2) to make the changes. MDAA-01-001EN
2
MDAA-01-040
3
4
MDAA-01-100EN
5 6
MJAA-01-009EN
5-12
OPERATING THE MACHINE Power Boost Switch Power boost switch (4) is located on the top of the right control lever. When power boost switch (4) is pushed, increased front attachment power will be supplied for about 8 seconds.
4
MDAA-01-344
5-13
OPERATING THE MACHINE Mode Switch One of three engine speed modes, ECO, PWR or H/P mode, can be selected using mode switch (1). ECO (Economy) Mode This mode slightly reduces the engine speed according to the operating condition. Digging power is same as the PWR mode. Although production is slightly reduced more than in the PWR mode, the fuel consumption and noise levels are reduced, allowing the machine to operate efficiently. PWR (Power) Mode Operate the machine in this mode when performing normal work. H/P (High Power) Mode Select H/P mode in order to increase workload. The maximum power of the machine can be utilized in this mode, increasing work efficiency when more power is required than in the PWR mode. In the H/P mode, the engine speed changes depending on load applied to the machine. This mode increases the engine speed at boom raise or arm roll-in operation when the engine control dial is in H position. H/P mode consumes a lot of fuel. WARNING: To ensure safety, be sure to turn mode dswitch (1) to the ECO 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.
5-14
1
MDAA-01-310
OPERATING THE MACHINE Operating Backhoe Use the appropriate arm and bucket for the work. (Refer to the "Bucket Types and Applications" in the Specifications section.) Pull the bucket toward the machine using the arm as the main digging force. When soil sticks to the bucket, remove it by moving the arm and/or bucket rapidly back and forth. Place the bucket teeth on the ground with the bottom of the bucket at a 45 degree angle to the ground. 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. When operating the arm, avoid bottoming the cylinder to prevent cylinder damage. IMPORTANT: When digging at an angle, avoid striking the tracks with the bucket teeth. When lowering the boom, avoid sudden stops that may cause shock load damage to the machine. When digging a deep excavation, avoid striking the boom or bucket cylinder hoses against the ground.
M107-05-037
MJAA-05-008
MJAA-05-007
Precaution for Arm Roll-In/Bucket Roll-In Combined Operation The bucket teeth will hit the boom if dWARNING: the bucket is rolled in with the arm fully rolled in, as
illustrated. When performing combined operation of arm roll-in/bucket roll-in or when rolling in the bucket with the arm fully retracted, be careful not to hit the boom with the bucket teeth.
M111-05-002
5-15
OPERATING THE MACHINE Grading Operation Operate the boom, arm, and the bucket in such a way so that the bucket teeth move horizontally, constantly keeping them perpendicular to the ground at the grading operation. IMPORTANT: Do not pull or push dirt with the bucket when traveling. Excess force will be applied on each part, and the machine may be damaged. 1. 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. 2. Arm roll-out operation is performed in the reverse way of step 1. 3. Do the slope finishing work in the same procedure as described in steps 1 and 2.
5-16
M104-05-017
OPERATING THE MACHINE Do Not Strike the Ground with Bucket Teeth Forcibly striking the bucket teeth on the dWARNING: ground may result in personal injury by the flying
debris. Also, this operation will shorten the service life of each part on the front attachment.
If the bucket teeth are forcibly struck on the ground, it shortens the service life of the front attachment parts (especially the bucket). When digging a hard gravel stratum, use dig up force of the bucket. Operate the boom, arm and the bucket simultaneously so that the bucket teeth efficiently bite into the ground. Flying debris may result in personal injury.
Avoid Hammer Work As the bucket body has the curved surface, dWARNING: hammer work or piling work is very dangerous. Doing
WRONG
so may damage the bucket and front attachment.
Do not attempt to use the bucket for hammer work and piling work. Doing so may damage the bucket and front attachment, causing personal injury.
M104-05-019
5-17
OPERATING THE MACHINE Avoid Abusive Operation
WRONG
Do not use travel and do not raise rear of the machine to use the machine's weight as additional digging force. Severe machine damage may result.
WRONG
WRONG
M104-05-018
Avoid Side Load the Bucket 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. Doing so may damage the front attachment and the swing system.
WRONG
M161-05-006
5-18
OPERATING THE MACHINE Do Not Use Wide Track Shoes on Rough Ground. Never use wide track shoes on rough ground such as rocks, sand, gravel or stumps. Wide track shoes are designed for soft ground. Failure to do so may result in shoe bending and/or shoe bolt loosening, and may damage other undercarriage components such as track link and rollers. (Refer to the "Shoe Types and Applications" in the Specifications section.)
5-19
OPERATING THE MACHINE Object Handling --- If Equipped When using machine for object handling dWARNING: 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 hose rupture 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.
SA-014
Rated lifting load table
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.
M1U1-05-004
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.
MJAA-01-008
5-20
M1U1-01-010
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.
5-21
OPERATING THE MACHINE Hydraulic Breaker and Hydraulic Crusher Selecting a breaker or crusher Select a breaker or crusher with the correct size and weight for your machine, considering the stability of the machine, hydraulic oil pressure and flow rate of the breaker, crusher or quick coupler. See your authorized dealer for correct breaker information. Precautions for Operation Carefully study the operation manuals of the breaker and crusher. To avoid damaging the machine, hydraulic breaker or crusher, follow the precautions given below. Precautions for connecting breaker or crusher piping Do not allow impurities to enter into the system when connecting/disconnecting the hoses of the breaker or crusher with the arm end piping. Before attaching the hydraulic breaker or crusher, be sure to loosen the plug of air breather (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 rubber hose before opening valve (1). When the breaker or crusher is not used, apply the cover to the pipe opening on the arm top and install the plug or cap into the hose end of the breaker or the crusher 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
1
OPEN
Valve
2 3
M1J1-13-001
5-22
OPERATING THE MACHINE Stop Valve Operation (ZX870-5 class)
Stop Valve 2
fNOTE:
The required stop valve is selected by selecting {Work Mode} on the monitor screen (refer to 5-10) for ZX470-5 class machines. Consult your nearest Hitachi dealer.
The stop valves are connected to pipes routed on the boom. Stop valves 2 illustrated in 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 in the right. When using a hydraulic crusher, turn the stop valves to the positions as illustrated in the right. After using the hydraulic crusher, be sure to turn the stop valves back to the breaker operation positions.
2nd RELIEF VALVE
Stop Valve 2 Stop Valve 1 M1J1-13-009
Stop Valve 1 Accumulator Breaker
Relief
Oil Tank
Accumulator
Crusher
Stop Valve 2
Relief
Oil Tank
M16J-12-004
5-23
OPERATING THE MACHINE Three-Way-Valve Operation (Machines equipped with the piping common to hydraulic breaker and crusher operation) (ZX870-5 class)
Boom
fNOTE:
The required stop valve is selected by selecting {Work Mode} on the monitor screen (refer to 5-10) for ZX470-5 class machines. Consult your nearest Hitachi dealer.
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
Line Filter
Boom
C/V
Crusher
M16J-12-005
Three-WayValve M16J-12-006
Flow Combining Valve Operation (Machines equipped with the piping common to hydraulic breaker and crusher operation) (ZX870-5 class)
fNOTE:
The required stop valve is selected by selecting {Work Mode} on the monitor screen (refer to 5-10) for ZX470-5 class machines. Consult your nearest Hitachi dealer.
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 or 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
M1J1-13-010
Flow Combining Valve
5-24
2 Pumps Combined Position
M1J1-13-007
OPERATING THE MACHINE Precautions for Breaker Operation WARNING: Machine stability is reduced as the dbreaker 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. WRONG
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.
M104-05-055
Avoid moving objects with breaker. Do not use the breaker and/or the bracket to move objects. Damage to the boom, arm, and/or breaker may result. Do not use the breaker and/or the swing function to move objects. Damage to the boom, arm, and/or breaker may result.
WRONG
M104-05-056
Avoid operating breaker at cylinder stroke end.
WRONG
Always operate the breaker by positioning the cylinder rods 100 mm or longer before the stroke end position. When operating the breaker with cylinders fully retracted or extended, hydraulic cylinders, arm or boom may be damaged.
M104-05-057
5-25
OPERATING THE MACHINE Stop operation if breaker hydraulic hoses jump abnormally.
Hose jumping abnormally
Change in breaker accumulator pressure or a damaged accumulator will cause abnormal hose jumping and may cause breaker and/or machine damage. Immediately stop the machine operation. Failure to do so may result in serious failure in the hydraulic system including pumps. Contact your nearest HITACHI dealer.
Accumulator
Hose jumping abnormally M104-05-058
Do not operate the breaker in water.
WRONG
Do not operate the breaker in water.
Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components. Rust, dust and water may enter into the hydraulic oil through the broken seal, damage to the hydraulic system may result.
Rod
M104-05-059
WRONG
Do not use breaker for lifting operation. The machine tipping over and/or breaker damage may result.
M104-05-060
WRONG
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
OK
OK
WRONG
5-26
RIGHT
M104-05-061
OPERATING THE MACHINE Operate the hydraulic excavator carefully to avoid hitting the boom or cab.
WRONG
When the arm rolled in with the breaker equipped, the chisel may come in contact with the boom or cab. Watch Out! Take care not to hit the boom or cab with the breaker M104-05-062
Do not operate breaker with the arm positioned vertically.
WRONG
Excessive vibration to the arm cylinder will occur, causing oil leakage.
M147-05-013
Press the breaker so that the chisel (the axis) is positioned and thrusted perpendicular to the object.
RIGHT
WRONG
Failure to do so may damage the chisel or may cause seized piston.
M147-05-014
Do not operate the breaker continuously longer than one minute. Continuously operating the breaker causes oil pressure to rise abnormally high or damages the accumulator. If an object could not be broken within one minute, apply the chisel to other locations, less than one minute for each location.
M116-05-011
M116-05-012
5-27
OPERATING THE MACHINE 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.
M116-05-013
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.
M116-05-014
Hit perpendicularly to the material surface. Unless the material surface is hit perpendicularly with the chisel, the bolts and chisel may be broken.
M116-05-015
5-28
OPERATING THE MACHINE Raising the front part of the undercarriage by pressing down the breaker may cause damage to the front attachment. 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
M147-05-016
5-29
OPERATING THE MACHINE Change Hydraulic Oil and Replace Full-Flow Filter Element Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hydraulic oil. Failure to adhere to proper maintenance intervals may result in damage to the base machine and the breaker. In order to extend the service life particularly of the hydraulic pump, change the hydraulic oil and the full-flow filter element at the specified frequency given below. (Refer to the "Hydraulic System" in the "MAINTENANCE" Section.) Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element Attachment
Availability
Bucket
100%
Hydraulic Breaker
100%
*Hydraulic Oil
Full Flow Filter Element Return Filter for the Breaker
2000
1000
4000 600
100
: Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the "Hydraulic System" in the "MAINTENANCE" Section.
Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element Average Breaker Operating Availability (%)
100 90
Element Replacement Intervals
80 70 60
Changing Interval when using 2000-hour life time hydraulic oil
50
Changing Interval when using 4000-hour life time hydraulic oil
40 30 20 10 0
0
500
1000
1500
2000
2500
Excavator Operating Hours
Breaker and Bucket are Used by Rotation Change the hydraulic oil and replace the full-flow filter element as well as the return filter for the breaker according to the breaker’s frequency of use, referring to the figure above. Be sure to replace elements when breaker has been operated for 100 hours continuously.
5-30
3000
3500
4000 MJAC-07-045
OPERATING THE MACHINE Replacement of Return Filter for Breaker
10
Hydraulic oil becomes hot and pressurized dWARNING: during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
1. Park the machine on a solid level surface. Lower the breaker to the ground. Stop the engine.
M1J1-07-006
2. Push pressure release button (10) on the air breather.
Front
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).
A
Inspect element (6) for metal debris to help in early detection of failures.
Cab
6. Install a new element (6). 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 as shown in the figure.
M111-05-009
9. Tighten drain plug (9).
Tightening Torque:44 N·m (4.5 kgf·m)
1
10. Tighten bolt (1).
Tightening Torque: 127 to 147 N·m (13 to 15 kgf·m) 2 (A810135) 3 (A810095) 4 5
6 (4357445) 7
8 (954493) 9 M111-05-010
5-31
OPERATING THE MACHINE Precautions for Crusher Operation Prevent machine tipping over and damage to the front attachment. Observe the following precautions for crusher operation. Machine stability is reduced as crusher dWARNING: is much heavier than bucket. When operating with a
crusher, the machine is more apt to tip over. 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. Failure to do so may result in damage to 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. Using the front attachment, do not raise the base machine off the ground with the arm cylinder fully extended. Failure to do so may result in damage to the arm cylinder. When a heavyweight attachment such as a crusher is installed, avoid quickly starting or stopping the front attachment. Failure to do so may result in damage to the front attachment. 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.
5-32
WRONG
M107-05-046
WRONG
M107-05-047
OPERATING THE MACHINE When the arm rolled in with the crusher equipped, the crusher may come in contact with the boom or cab.
WRONG
Watch Out! Take care not to hit the boom or cab with the crusher M1G6-05-009
When operating the crusher up high with the boom fully raised, be careful of falling objects.
WRONG
M107-05-048
When operating the crusher on a floor in a building, first confirm that the floor has sufficient strength to support the load caused by crushing, in addition to the machine weight. The load equivalent or higher than the machine weight may be applied on floor depending on the operation method.
WRONG
M107-05-049
5-33
OPERATING THE MACHINE 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. 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.
5-34
OPERATING THE MACHINE Attachment Attachment Example commercial attachment models (breakers) for excavators are shown in the following table. When an attachment other than the standard bucket is installed on the machine, the machine stability will be different. If a heavy attachment is used, not only will controllability be affected but also machine stability will be reduced, possibly causing safety hazard. Thoroughly read and understand the base machine operator's manual and the attachment manual to prevent accidents. Breaker (ZX470-5 Class) Maker NPK Model GH18 Weight kg 2865 Flow Rate L/min 220 to 290 Operating 15 to 17 Pressure (153 to 173) MPa (kgf/cm2)
F-30 1200 160 to 210
Furukawa F-35 F-45 1210 1590 175 to 220 200 to 250
F-70 2250 250 to 340
MKB2100V 2000 135 to 180
Konan Electric MKB2500V MKB3000V 2300 3300 150 to 225 170 to 260
14.5 to 18 (148 to 184)
16 to 18 (163 to 184)
16 to 18 (163 to 184)
16 to 18 (163 to 184)
14.7 to 17.7 (150 to 180)
14.7 to 17.7 (150 to 180)
14.7 to 17.7 (150 to 180)
TNB-150 1210 160 to 200
TNB-160 1590 150 to 200
Toukuu TNB-190 TNB-220 2250 2000 160 to 210 180 to 220
TNB-230 2300 180 to 230
TNB-310 3300 240 to 300
13.7 to 17.7 (140 to 180)
12.7 to 17.7 (130 to 180)
13.7 to 17.7 (140 to 180)
12.7 to 17.7 (130 to 180)
13.7 to 17.7 (140 to 180)
Breaker (ZX470-5 Class) Maker Jacty Model NJB233 NJB240 Weight kg 2865 1200 Flow Rate L/min 200 to 250 220 to 290 Operating 13.7 to 15.7 14.7 to 16.7 Pressure (140 to (150 to 170) 2 MPa (kgf/cm ) 160)
12.7 to 17.7 (130 to 180)
Breaker (ZX470-5 Class) Maker Model
Okada TOP300
Weight kg 2480 Flow Rate L/min 160 to 215 Operating 14 to 18 Pressure (143 to 184) 2 MPa (kgf/cm )
Atlas Copco Krupp
RUMMER G90CITY/ G110CITY/ PRO PRO 3150 3800 210 to 310 220 to 320
3800 220 to 350 15.5 to 16.5 (158 to 168)
HM1500S
HM2300S
HM2600S
G88CITY
2200 140 to 180
3000 210 to 270
4200 250 to 320
2370 160 to 230
16 to 18 (163 to 184)
16 to 18 (163 to 184)
16 to 18 (163 to 184)
14 to 15 14 to 15 14 to 15.5 (143 to 153) (143 to 153) (143 to 158)
RM145 2255 165 to 200
RM150 2475 175 to 220
EURO RAM RM160 2750 185 to 260
RM180 3645 245 to 310
RM195 4615 295 to 360
13.5 to 15.8 (138 to 161)
14 to 15.8 (143 to 161)
14 to 15.8 (143 to 161)
14 to 15.8 (143 to 131)
15 to 16.3 (153 to 166)
Breaker (ZX470-5 Class) Maker Model Weight kg Flow Rate L/min Operating Pressure MPa (kgf/cm2)
Montabert V45 SHD V55 SHD 2547 3480 180 to 265 240 to 320 16.5 (168)
16.5 (168)
5-35
G100CITY
OPERATING THE MACHINE Breaker (ZX870-5 Class) Maker NPK Model GH30 GH40 Weight kg 5470 7750 Flow Rate L/min 280 to 350 300 to 400 Operating 16 to 18 16 to 18 Pressure (163 to 184) (163 to 184) 2 MPa (kgf/cm )
Furukawa F-70 2250 250 to 340
Konan Electric MKB6000V MKB7000V 5900 6500 220 to 330 270 to 380
Okada TOP800 5600 280 to 380
Toukuu TNB-310 TNB-400 3046 4326 240 to 300 280 to 390
16 to 18 (163 to 184)
14.7 to 17.7 (150 to 180)
15 to 18 (153 to 184)
13.7 to 17.7 (140 to 180)
14.7 to 17.7 (150 to 180)
13.7 to 17.7 (140 to 180)
Breaker (ZX870-5 Class) Maker
Atlas Copco Krupp
Montabert
RUMMER
Model
HM3000S
HM4000S
V65 SHD
Weight kg Flow Rate L/min Operating Pressure MPa (kgf/cm2)
5800 310 to 390
7000 360 to 450
5655 380 to 420
G110CITY/ PRO 3800 220 to 320
16 to 18 (163 to 184)
16 to 18 (163 to 184)
16.5 (168)
14 to 15.5 (143 to 158)
5-36
EURO RAM
G100CITY
G130CITY
RM195
RM215
3800 220 to 350
7000 300 to 400
4615 295 to 360
7425 330 to 425
15.5 to 16.5 (158 to 168)
15 to 17 (153 to 173)
15 to 16.3 (153 to 166)
15 to 16.3 (153 to 166)
OPERATING THE MACHINE How to Lower Boom In Case of Emergency and When Engine Stops
2
In case the engine suddenly stops and the engine cannot restart, lower the boom in the following procedures.
1
IMPORTANT: Never loosen screw (2) more than 4 turns. Screw (2) may come off. 1. Loosen lock nut (1) in the control valve at the right. Loosen screw (2) two turns. The boom lowering speed can be somewhat adjusted by loosening screw (2) more. IMPORTANT: Excessive leakage may result if the screw and the lock nut are tightened insufficiently. Be sure to retighten the screw and the lock nut to specifications. 2. After the boom is lowered, tighten screw (2) and tighten lock nut (1) to the specifications below.
Locknut (1) Bolt (2)
Bolt Size
Tightening torque
M6 M6
15 N·m 6 N·m
MJAA-05-003 Emergency Valve
2
1
Hexagonal Hole Width Across Flats 10 3
MJAA-05-002
5-37
OPERATING THE MACHINE Precautions for After Operations After finishing the day's operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods are present. (Refer to the group for “Parking the Machine” in the DRIVING MACHINE section.) Fully refill the fuel in the fuel tank. Clean the machine. 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
5-38
TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations. IMPORTANT: When transporting, disassembling or assembling the machine other than transporting the machine on public roads, consult your nearest Hitachi dealer. When transporting the machine using a trailer, check the width, height, length and weight of the trailer with the machine loaded. Note that transporting the weight and dimensions may vary depending on the type of shoe or front attachments installed. Investigate beforehand the conditions of the route to be traveled, such as dimensional limits, weight limits, and traffic regulations. When transporting a machine with the side frame, be sure to retract the side frame before loading the machine onto trailer bed for transportation. The overall width of the machine varies depending on the shoe width. In some cases, getting the permission from the local authority concerned or disassembling the machine to bring it within dimensional limits or weight limits of local regulations may become necessary. Notify the nearest dealer that you are transporting the unit.
6-1
TRANSPORTING Loading/Unloading on a Trailer
dWARNING: Be sure to use a loading dock or a ramp for loading/unloading. Always load and unload the machine on a firm, level surface. Ramp/Loading Dock: 1. Before loading, thoroughly clean the ramps, loading dock and flatbed. Dirty ramps, loading docks, and 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.
6-2
TRANSPORTING Loading/Unloading
dWARNING: Always turn the auto-idle switch [A/I OFF] and turn the mode switch to ECO position when loading or unloading the machine. In the auto-idle mode, speed may automatically increase. The engine speed may unexpectedly change while performing the muffler filter regeneration. Turn the muffler filter regeneration switch to inhibited position. Always select the slow speed mode with the travel mode switch. Run the engine at slow idle to ensure the machine travels at a slow pace. Never steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover. NEVER attempt to change directions whilst positioned on the ramp. 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 as the balance may be lost. If the front attachment is not fitted, reverse onto the trailer. Extreme care must be taken when swinging the upper structure when the machine is on the trailer flatbed.
Loading If the front attachment is not fitted, reverse onto the trailer. 1. Load the machine so that the centerline of the machine aligns with the centerline of the trailer flatbed.
15 ° or less
2. Drive the machine onto the ramp slowly. In cold weather, be sure to warm up the dCAUTION: machine before loading or unloading it. 3 Securely close cab windows, overhead window, cab door and covers and tighten tank caps to prevent entry of wind and water. Lock all doors, covers and caps if they have a lock. Put covers on the opening of mufflers. 4. Put all mirrors and the radio antenna away correctly.
6-3
M107-06-018
TRANSPORTING Fastening Machine for Transporting Fasten chains or cables to the machine dWARNING: frame. Do not place chains or cables over or against the hydraulic lines or hoses.
1. Place cog stoppers or blocks in front of and behind the tracks to help secure the unit. 2. Fasten each corner of the machine and front attachment to the trailer with appropriate strength of chains or cables.
MJAA-06-002
Unloading The rear end of the flatbed where it meets dWARNING: the ramp is a sudden bump. Take care when traveling over it.
MJAA-06-003
6-4
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.
SA-005
If there is any problem with your machine, repair it before operating or contact your authorized dealer. IMPORTANT: Use only recommended fuel and lubricants. Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown. Failure to use recommended fuel, lubricants, 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. Never adjust parts of engine fuel system or hydraulic equipment. Using bad quality fuel, drainage agent, fuel additives, gasoline, kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and injector nozzles dirty. It also affects the engine, leading to malfunction. Use Hitachi genuine high performance filter.
7-1
MAINTENANCE Body Information Controller This machine provides a body information controller that stores machine operation information for preventive maintenance. When maintaining the machine, our authorized service man may down load the stored information. Consult with your nearest Hitachi dealer for detailed function of this device. Communication Terminal Operation It is not necessary to check or operate the communication terminal however if any abnormality is found, consult your nearest Hitachi dealer. Before installing any covering attachment such as a head guard, consult your nearest Hitachi dealer. Never spray water on the communication terminal and the wirings. Inquire on the proper way to recycle or dispose of oil, fuel, coolant, filters, batteries and other waste from your local environmental or recycling center, or from your authorized dealer. Hitachi machine models described in this manual are classified as shown in the table below. Model Std. Model
Std. Specification
ZX470-5G, 470LC-5G, 470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G ZX870-5G, 870LC-5G, 870H-5G, 870LCH-5G, 870LCR-5G
7-2
MAINTENANCE Check the Hour Meter Regularly Refer to the List of Check and Maintenance for information about lubricants, check and adjustment intervals. The maintenance guide table is affixed in the back of the tool box cover. Refer to the page 7-8. This manual recommends grouping the intervals into three categories as follows: Daily Check : To be conducted daily before operation Monthly check : To be regularly conducted once per month Annual check : To be regularly conducted once per year Check and maintenance intervals shown in this manual are those for the machines to be operated under normal conditions. In case the machine is operated under more severe conditions, shorten the intervals.
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.
7-3
MAINTENANCE Layout ZX470-5 class
33 1
32
31
2
3
30 27
4
5
26
6
7
28 29
8
25
9 10
24 23
22
21
20 19
15
18 17 16
1- 2- 3- 4- 5- 6- 7- 8- 9- 10-
Arm Cylinder Boom Washer Tank Swing Device Fuel Tank Reserve Tank Control Valve Air Cleaner Radiator, Oil Cooler Counterweight
11- 12- 13- 14- 15- 16- 17- 18- 19- 20-
Shoe, Track Link Engine Muffler Engine Oil Filter Main Pump Travel Reduction Gear Pilot Filter Drain Filter Upper Roller Swing Bearing
21- 22- 23- 24- 25- 26- 27- 28- 29- 30-
7-4
Lower Roller Hydraulic Oil Tank Track Adjuster Front Idler Cab Boom Cylinder Side Cutter Tooth Bucket Link A
14
13
11 12 TJAC-01-02-001
31- Link B 32- Bucket Cylinder 33- Arm
MAINTENANCE
ZX870-5 class
1 38 2 37
3 4 5
36 31
32
35
6
7
8
9
12
10
30
33
11
29
34
13
28
14
27 26 25 24
15 23
16 22
1- 2- 3- 4- 5-
Arm Cylinder Boom Washer Tank Swing Bearing Tool Box, Electric Grease Gun, Auto-Lubrication Device 6- Fuel Tank 7- Swing Device 8- Control Valve 9- Oil Cooler, Fuel Cooler 10- Reserve Tank
11- 12- 13- 14- 15- 16- 17- 18- 19- 20-
Radiator, Inter Cooler Air Cleaner Engine Counterweight Muffler Main Pump Fan Pump Shoe, Track Link Travel Reduction Gear Lower Roller
21
20 21- 22- 23- 24- 25- 26- 27- 28- 29- 30-
7-5
19
18
Fuel Filter Pilot Filter Track Frame Pump Drain Filter Hydraulic Oil Tank Track Adjuster Upper Roller Front Idler Battery Cab
17 TJBE-01-02-001 31- 32- 33- 34- 35- 36- 37- 38-
Boom Cylinder Side Cutter Tooth Bucket Link A Link B Bucket Cylinder Arm
MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed to the reverse side of the tool box cover. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly. Symbol Marks The following marks are used in the maintenance guide table. Grease (Front Joint Pin, Swing Bearing, Swing Gear)
Hydraulic oil filters (Pilot Filter, Hydraulic Oil Tank Filter, Suction Filter)
Gear Oil (Pump Transmission, Travel Reduction Device, Swing Reduction Device)
Air Cleaner Element
Engine Oil
Coolant (Long-Life Coolant)
Engine Oil Filter
Fuel Filter (Fuel Main Filter, Pre-Filter)
Hydraulic Oil
7-6
MAINTENANCE Maintenance Guide Table 13
14
15
10
12
10
6
1 2
11
3 4 5 6
Lubrication Interval (hours)
10
9
8
7
MJAC-07-041
f NOTE: The illustration shows ZX870-5 class. 1 2
Item Hydraulic Oil Hydraulic Oil Filter (Full Flow)
Page 7-58 7-62
3
Fuel Filter (Main/Pre)
7-78
4
Gear Oil (Pump Transmission) (ZX870-5 Class)
7-47
5 6
Engine Oil Filter Gear Oil (Travel Device) Hydraulic Oil Filter (Pilot) Hydraulic Oil Filter (Pump Drain)
7-44 7-51 7-64 7-63
7
8 9 10 11 12 13 14 15
7-7
Item Hydraulic Oil Filter (Suction) Grease
Page 7-58 7-27
Grease (Every 10 hours for the first 100 hours, every 50 hours after that) Hydraulic Oil Filter (Air Breather) Coolant (Long-Life Coolant) Engine Oil Air Cleaner Element Gear Oil (Swing Reduction Gear)
7-25 7-66 7-87 7-44 7-82 7-49
MAINTENANCE Preparations for Inspection and Maintenance Except in special cases, park the machine by following the procedure before servicing the machine. 1. Park the machine on a level and solid surface. 2. Lower the bucket to the ground.
M104-07-021
3. Turn the auto-idle switch OFF. 4. Turn the engine control dial to the slow idle position and run the engine for 5 minutes to cool the engine. 5. Turn the key switch OFF to stop the engine. Remove the key. Be sure to place pilot control shut-off lever (1) to the LOCK position. 6. After putting a tag (2) for "Under Serving" on the easy-tosee cab door or control lever, begin the work. WARNING: Never attempt to maintain the machine dwhen the engine is running in order to prevent the
1 2
accident. If maintenance work while engine running is unavoidable, strictly comply with the following items.
One person should take the operator's seat to be ready to stop the engine any time while communicating with other workers. When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled.
MDAA-07-028
If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off. Do not drop or insert parts and tools into the moving parts. Move pilot control shut-off lever (1) to LOCK position so that the front attachment will not move. Never touch the control levers and pedals. If operating the control levers or pedals is unavoidable, signal co-workers to evacuate to safer place.
SA-2294
SA-026
7-8
MAINTENANCE Hood and Access Covers
1
ZX470-5 class
d WARNING: Do not keep the hood and access covers open when the machine is parked on a slope, or while the wind is blowing hard. The hood or access 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. Engine Cover (Front)
When opening the engine cover (front or rear), hold the handle on the engine cover, raise the cover until the cover is secured with catch (1).
MJAC-07-014
1
After opening the right and/or left access cover, be sure to insert rod (2) into cover lock hole (3) to hold the cover. When opening the front left/right cover, open the rear left/ right cover first. Then, pull to open the front left/right cover.
Engine Cover (Rear)
3
MJAC-07-015
2
2
Rear Left Cover
2
3
MJAC-07-019
Rear Right Cover
3
MJAC-07-024
2 3
Front Left Cover
MJAC-07-018
7-9
Front Right Cover
MJAC-07-023
MAINTENANCE ZX870-5 class
2
d WARNING: Do not keep the hood and access covers open when the machine is parked on a slope, or while the wind is blowing hard.
1
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. When opening the engine cover, open the engine front door first. Then, pull to open the engine cover. When closing the engine front cover, close the engine cover first. Then, close the engine front cover.
3 4 Engine Cover, Front Door
MJAC-07-032
1
When opening the engine cover and/or air cleaner cover, unlock the catches (2 places), hold the handle on the cover, and raise the cover until the lock is secured with lock groove (2). After opening the engine front door or left access cover (front and rear), be sure to insert rod (3) into cover lock hole (4) to hold the cover. After opening the right access cover (front and rear), be sure to insert rod (3) into cover lock hole (2) to hold the cover.
2
MJAA-07-074
Air Cleaner Cover 4
3
3 4
3
Front and Rear Left Cover
MJAA-07-014
2 3
2
Rear Right Cover
MJAA-07-016
7-10
Front Right Cover
MJAC-07-039
MAINTENANCE Battery Disconnect Switch (Optional) IMPORTANT: Never attempt to turn the battery disconnect switch OFF while engine running. Failure to do so may damage the electrical system. The battery disconnect switch is different from the engine start key switch. When the battery disconnect switch is turned OFF, the electrical system will completely be isolated from the battery. No current will flow through the whole electrical system. Before turning the battery disconnect switch OFF, be sure to turn the key switch OFF and wait for 30 seconds or more after the engine stops. If the battery disconnect switch is turned OFF within 30 seconds after the engine stops, it may result in malfunction of the electrical system.
ZX470-5 class
MJAC-07-050
Use the battery disconnect switch only for the following purposes. Before maintaining and repairing the electrical system Before storing the machine for long period (Discharge prevention) Before welding the machine. Before replacing the battery. The battery disconnect switch is located in the battery box.
7-11
ZX870-5 class
MJAC-07-051
MAINTENANCE MEMO
.................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. ..................................................................................................................................................................................................
7-12
MAINTENANCE Daily Check
Engine
Upperstructure
Undercarriage
Working Device
Others
Check Item 1. Level of engine oil and coolant 2. Starting easiness, exhaust gas color, and noise 3. Oil and water leaks, damage to hoses and pipe lines 4. Clogging and damage to radiator, oil cooler and intercooler 5. Looseness and missing of mounting bolts and nuts 6. Drain Fuel Filter 1.Fuel level, leaks, contamination and drainage of fuel in tank 2. Hydraulic oil level, leaks and contamination of hydraulic oil tank 3. Movement, play and operating force of all control levers 4. Operation of all hydraulic components, oil leaks and damage to pipe lines and hoses 5. Deformation, break and abnormal noise of upper structure 6. Looseness and missing of mounting bolts and nuts 7. Washer Fluid 1.Sag, wear and break of crawler 2.Oil leaks and wear on upper/lower rollers and front idlers 3.Oil leaks from travel devices 4.Looseness and missing of mounting bolts and nuts 1.Check cylinders, pipe lines and hoses for oil leaks and damages. 2. Wear and damage of the bucket 3. Check bucket teeth for looseness, wear and missing 4. Lubrication state of the working device 5. Check for pin anti-extraction pins, stoppers, rings and bolts for damage 6. Looseness and missing of mounting bolts and nuts 7. Grease leaks and damage of auto-lubrication piping and hoses 1. Operation of instruments, switches, lights and buzzer/horn 2. Function of parking brake 3. Deformation and break of head guard 4. Abnormal outside appearance of machine 5. Wear and damage of the seat belt
Conduct daily check before the machine is operated.
7-13
Reference Page 7-43, 86 7-68, 82, 85 7-89 7-115 to 139 7-76 7-72 to 75 7-56 to 57 7-68
7-115 to 139 7-111 7-110, 122, 134 7-51 7-115 to 139 7-68 7-103 7-25 to 26 7-125, 137 7-115 to 139 1-6 to 102
7-108
MAINTENANCE Maintenance Guide A. Greasing Parts
Quantity
Boom Foot, Boom Cylinder Bottom Bucket and Link Pins
1. Front Joint Pins
Others
Interval (hours) 10
50
100 250
500
1000 2000
Page
4
7-25
9
7-25
7
7-26
2. Swing Bearing
3
3. Swing Internal Gear
1
7-27
7-28
: Grease at an interval of every 10 hours for the first 100 hours. : In case excavations are performed in water, grease the pin after operation is complete. : Add grease if necessary during maintenance.
f NOTE: When the auto-lubrication system is operating, grease the bucket, link pins and the swing bearing by using a grease gun.
B. Engine Parts
Quantity
1. Check Engine Oil Level 2. Change Engine Oil 3. Replace Engine Oil Filter
ZX470-5 class ZX870-5 class
1 55 L 55 L 1
7-14
10
50
Interval (hours) Page 100 250 500 1000 2000 7-43 7-44 7-44
MAINTENANCE C. Transmission Parts
Quantity
Check Oil Level Pump Transmission (ZX870Change Oil 5 class) Clean Air Breather Check Oil Level 2. Swing Device ZX470-5 class Change Oil ZX870-5 class Check Oil Level 3. Travel Reduction Gear ZX470-5 class Change Oil ZX870-5 class 1.
1 6.2 L 1 2 6.5 L×2 15.7 L×2 2 11 L×2 19 L×2
10
50
Interval (hours) Page 100 250 500 1000 2000 7-47 7-48 7-48 7-49 7-50 7-51 7-52
D. Hydraulic System Parts
Quantity
1. Check Hydraulic Oil Level 2. Water drain from hydraulic oil tank ZX470-5 class 3. Change Hydraulic Oil ZX870-5 class 4. Suction Filter Cleaning 5. Replacement of Full-Flow Filter 6. Replace Pump Drain Filter 7. Replace Pilot Oil Filter 8. Replace Air Breather Element Check Hoses and Lines for Leaks and Tightness 9. Check of hose and pipe line for Cracks and Bending
1 1 510 L 1042 L 1 1 1 1 1
Interval (hours) Page 10 50 100 250 500 1000 1500 2000 2500 4000 7-56 7-57
Each time when hydraulic oil is changed
7-58 7-58 7-62 7-63 7-64 7-66
−
7-67
−
7-67
: Changing interval differs according to the brand of hydraulic oil used, kind of filter element or average attachment operating availability. Refer to the "changing intervals of hydraulic oil and full flow filter element." See recommended oil chart.
7-15
MAINTENANCE E. Fuel System Parts
Quantity
1. 2. 3. 4. 5.
Drain Fuel Tank Sump Check Water Separator Replace Fuel Main Filter Replace Fuel Pre-Filter Element Clean Feed Pump Strainer Check Fuel Hoses for Leaks and Cracks. 6. Check Fuel Hoses for Cracks and Bending.
1 1 1 1 1 − −
10
50
Interval (hours) Page 100 250 500 1000 2000 7-74 7-75 7-77 7-78 7-80 7-81 7-81
F. Air Cleaner Parts
Quantity Clean
1
Replace
1
After cleaning 6 times or 1 year
7-82
Replace
1
When outer element is replaced
7-82
1. Air Cleaner Outer Element 2. Air cleaner Inner element
Interval (hours) Page 10 50 100 250 500 1000 2000 (Or when indicator 7-82 lit)
7-16
MAINTENANCE G. Cooling System Parts
Quantity
1. Check Coolant Level 2. Change Coolant
ZX470-5 class ZX870-5 class
Outside Inside Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 4. class) Front Screen 5. Clean Air Conditioner Condenser 3. Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Core
10
50
1 61 L 112 L 1 1
Interval (hours) Page 100 250 500 1000 2000 7-85 Twice a year *
7-86
Once a year
7-88 7-88
1
7-88
1
7-88
: Shorten the maintenance interval when the machine is operated in dusty areas. : Maintenance required only during first time check. * : When genuine Hitachi Long-Life Coolant is used, change every two years or 4000 operating hours, whichever comes first. IMPORTANT: Use fresh water or normal tap water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 60 %. If a coolant mixed with less than 30 % of Hitachi Long-Life Coolant is used, service life of the cooling parts may be shortened due to damage by freezing or corrosion of coolant system parts. If mineral-rich water is used for coolant, water stain or scale may build up inside the engine or radiator, causing overheat due to deterioration of coolant performance.
7-17
MAINTENANCE H. Air Conditioner
Clean
1
Replace
1
Clean Replace
2. Check Air Conditioner
1 1 1
Interval (hours) Page 10 50 100 250 500 1000 2000 7-89 When the filters are severely clogged or 7-89 after cleaning 6 times 7-89 7-89 7-91
3. Adjust Compressor Belt Tension
1
7-92
4. Check mounting bolts for looseness.
−
7-92
5. Check at Preseason and Off-Season
−
Parts Circulating Air Filter 1. Fresh Air Filter
Quantity
Twice a year
7-93
I. Electrical System Parts 1. Battery 2. Replacing Fuses
Quantity
Check Electrolyte Level Check Electrolyte Specific Gravity Replace
2 2 −
7-18
10
50
Interval (hours) Page 100 250 500 1000 2000 Every month 7-96 Every month 7-97 As required
7-99
MAINTENANCE J. Miscellaneous Parts 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Check and Replace Bucket Teeth Change Bucket Adjust Bucket Linkage Remove Travel Levers Check and Replace Seat Belt Check Windshield Fluid Level Adjustment of Track Tension Clean Cab Floor Retighten Cylinder Head Bolt Inspect and Adjust Valve Clearance Check of Fuel Injection Timing Measure Engine Compression Pressure Check Starter and Alternator Check Water Pump Check and Replace Injection Nozzle Check Gas Damper
17. Check Cushion Rubber of Handrail (ZX470-5 class) Tightening and Retightening Torque of Bolts and Nuts 19. Check O-rings in Bucket 18.
Quantity − − 1 2 1 1 2 − − − − − − − − − 2 −
Interval (hours) Page 100 250 500 1000 2000 4000 7-101 As required 7-104 As required 7-107 As required 7-108 Every 3 years 7-108 As required 7-109 7-110 As required 7-113 *As required 7-114 * 7-114 *As required 7-114 * 7-114 * 7-114 * 7-114 7-114 *As required 7-115 Every 2 years or 4000 hours whichever comes 7-115 first 10
50
−
: Maintenance required only during first time check.
f NOTE: * Contact your nearest Hitachi dealer for maintenance. Instruction plate for the recommended grease and lubricants is affixed inside the tool box cover.
7-19
7-115 7-140
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. These parts may cause serious safety/fire hazards due to deterioration, wear, or fatigue being attributed to material aging or repeated operation. 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. Consult your authorized dealer for correct replacement. Periodic Replacement Parts
Replacement Intervals
Engine Base Machine Working Device
Hydraulic System
Fuel hose (Fuel tank, Filter to Engine)
Every 2 years or 6000 hours whichever comes first
Fuel hose (Engine, Fuel tank) Oil filter hose (Engine to oil filter)
Every 2 years or 6000 hours whichever comes first
Heater hose (Heater to engine)
Every 2 years or 6000 hours whichever comes first
Pump suction hose
Every 2 years or 6000 hours whichever comes first
Pump delivery hose
Every 2 years or 6000 hours whichever comes first
Swing hose
Every 2 years or 6000 hours whichever comes first
Travel high pressure hose
Every 2 years or 6000 hours whichever comes first
Boom cylinder line hose
Every 2 years or 6000 hours whichever comes first
Arm cylinder line hose
Every 2 years or 6000 hours whichever comes first
Bucket cylinder line hose
Every 2 years or 6000 hours whichever comes first
Pilot Hose
Every 2 years or 6000 hours whichever comes first
Every 2 years or 6000 hours whichever comes first
Seat Belt
Every 3 years
f NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.
7-20
MAINTENANCE Kind of Oils Brand Names of Recommended Grease Where to be Bucket, Arm and Boom, Swing Gear, applied Swing Bearing, etc. Manufacturer –20 to 45 °C (–4 to 113 °F) Nippon Koyu SEP 2 1 British Petroleum BP Energrease LS-EP2 Caltex Oil Multifax EP2 Esso Beacon EP2 Idemitsu Kosan Daphne Coronex Grease EP2 Mobil Oil Mobilux EP2 Nippon Oil Epinoc Grease AP2 Shell Oil Shell Alvania EP2 2
fNOTE:
The machine shipped from the factory is filled with lubricants marked with . 1 Front Joint Pin and Swing Bearing 2 Swing Gear
IMPORTANT: Use only genuine Hitachi engine oil as shown below. Or use JASO DH-1 or equivalent engine oil. Brand Names of Recommended Engine Oil Kind of Oil Engine Oil Application Engine Crank Case Air Temp. -20 to 30 ˚C -15 to 45 ˚C (-4 to 86 ˚F) (5 to 113 ˚F) Manufacturer Super wide Super wide Hitachi DH-1 10W30 DH-1 15W40
JASO DH-1
7-21
MAINTENANCE Brand Names of Recommended Gear Oil Application Kind of Oil Air Temp.
Manufacturer Hitachi British Petroleum Caltex Oil Esso Idemitsu Kosan Mobil Oil JX Nippon Oil Shell Oil Remarks
fNOTE:
Swing and Travel Reduction Gear Gear oil –20 to 45 °C (–4 to 113 °F) Gear oil BP Gear oil Thuban Esso Gear oil Apollo Gear Mobilube Gear Lube SP90 Shell Spirax API GL 4 Class
GL-4 90 SAE80W-90 SAE 90 GP80W-90 HE90 GX80W-90 EP90
The machine shipped from the factory is filled with oil marked
.
Brand Names of Recommended Pump Transmission Oil ZX870-5 Class Application Pump Transmission Kind of Oil Engine Oil or Gear Oil Air Temp. –20 to 45 °C –10 to 35 °C 25 to 45 °C Manufacturer (–4 to 113 °F) (14 to 95 °F) (77 to 113 °F) BP Vanellus C3 British Petroleum 30 40 RPM DELO 300 Oil Caltex Oil 30 40 Essolube D-3 Esso 30 40 Apolloil diesel motive Apolloil super wide Idemitsu Kosan 15W-40 S-330 CF S-340 Mobil Delvac Mobil Oil 1330 1340 Hidiesel S3 –20 to 35 °C JX Nippon Oil 15W-40 (–4 to 95 °F) 10W-30 Rymla D Shell Oil 30 40 Remarks API CD Class
fNOTE:
The machine shipped from the factory is filled with oil marked
7-22
.
MAINTENANCE Brand Names of Recommended Hydraulic Oil 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
Hydraulic Oil Hydraulic System 4000 hours
2000 hours –20 to 45 °C (–4 to 113 °F)
Super EX 46HN Super Hydro 46 WRHU Bartran HV46 Rando Oil HD46 Rando Oil HD46 Chevron AW46 NUTO H46 DTE 25 Tellus Oil 46 Anti-wear type hydraulic oil
fNOTE: 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 4000 cSt at -40 °C
When the atmospheric temperature is below -40 °C: Contact your authorized dealer.
High Temperature Viscosity: More than 6.5 cSt 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.
7-23
MAINTENANCE Recommended Oil Viscosity Where to be Applied
Kind of Oil
-30
Air Temperature (degrees Celsius) -20 -10 0 10 20 30
45
Engine Oil Pan
Engine Oil
Pump Transmission Swing Device Travel Device Hydraulic System (Hydraulic Oil Tank)
Engine Oil
Super Wide DH-1 10W30 Super Wide DH-1 15W40 Idemitsu Kosan S-330
Gear Oil
Hitachi Gear Oil GL-4_90
Hydraulic Oil
Super EX46HN
Diesel Fuel
ASTM Grade No.2-DS15 ASTM Grade No.2-DS500 ASTM Grade No.1-DS15 ASTM Grade No.1-DS500
Grease fitting
Lithium Grease
SEP Grease
Radiator
Coolant
Genuine Hitachi LLC (Long-Life Coolant)
Fuel Tank
7-24
MAINTENANCE A. Greasing Front Joint Pins Bucket --- every 10 hours Others --- every 10 hours for the first 100 hours every 50 hours after that You can also lubricate the machine by using grease fittings provided on each section of the machine without using the auto-lubrication system. Follow the instructions below to lubricate the machine.
MJAA-07-011 Perpendicular to the Ground
f NOTE: When lubricating the machine with the backhoe
front attachment, fully extend the arm cylinder, control the bucket cylinder in such a way so that the bucket bottom plate is kept perpendicular to the ground, and lower the boom to the ground by using boom cylinder as shown in figure right. Setting the machine in this position allows you to access all lubricating spots.
Lubricate all fittings shown in the figure. The fast-filling device is provided to easily lubricate high lubrication spots. Boom Foot
M162-07-005
Boom Cylinder Bottom Side
M162-07-034
Bucket and Link Pins Lubricate the bucket every 10 hours.
M1J1-07-058
7-25
MAINTENANCE Boom and Arm Joint Pin, Arm Cylinder Rod Pin and Bucket Cylinder Bottom Pin
M162-07-006
Boom Cylinder Rod Pins and Arm Cylinder Bottom Pin
M162-07-005
7-26
MAINTENANCE Swing Bearing --- every 500 hours CAUTION: Before lubricating the machine, lower the dbucket on the ground, stop the engine and pull the pilot control shut-off lever to the LOCK position.
Three grease fittings are provided. Greasing Method 1. Lower the bucket on the ground, stop the engine and pull the pilot control shut-off lever to the LOCK position. Then, lubricate the swing bearing. 2. Raise the bucket several inches off the ground and rotate the upperstructure 45° (1/8 turn). 3. Repeat steps 1 and 2 three times. 4. Apply grease to the swing bearing until grease can be seen escaping from the swing bearing seals.
Take care not to supply excessive grease.
7-27
M111-07-010
MAINTENANCE Swing Internal Gear --- every 500 hours CAUTION: Before lubricating the machine, lower the dbucket on the ground, stop the engine and pull the pilot control shut-off lever to the LOCK position.
1. Remove cover (1) located at the front side of the upperstructure frame. 2. Ensure the grease is evenly and nicely applied on top surface of all internal gear teeth of the swing bearing without contamination. Add approximately 0.5 kg of grease, if required.
1 M1J1-07-024
3. If the grease is contaminated, remove grease by opening cover (2) at the undercarriage side and replace with clean grease.
Grease Capacity (L) Model
Capacity
ZX470-5 class
17 L
ZX870-5 class
22 L
f NOTE: If excessive grease is filled in the swing gear, grease
2
may enter the gear case of the swing device while swinging the upperstructure. Be sure to fill the same amount of grease as you removed.
M116-07-042
2
Check the direction of cover (2). If the cover is installed on the wrong direction, water may enter into the unit. Replace packing (4) if it deteriorates.
4
Correct
Incorrect MDAA-07-029
7-28
MAINTENANCE Electric Grease Gun (Optional)
d CAUTION: Since the electric grease gun is not a waterresistance type, avoid leaving it in a place exposed to rain and water. Do not use the electric grease gun in rain fall. Failure to do so may lead to an unexpected accident such as leak. No specified daily maintenance is required. Take care not to allow any part of the grease gun, especially motor section, to come in contact with other objects or do not leave the grease gun contaminated, possibly resulting in unexpected injury such as electric shock. Always keep the grease gun clean by wiping off contamination. Failure to do so may cause the grease gun to slip down resulting in possible personal injury.
d WARNING: Do not operate an electric grease gun in explosive atmosphere. An electric tool may create sparks and ignite combustible fluid, dust, or fumes. Avoid electrifying the grease gun in damp or wet locations. WARNING: The grease gun develops high pressure dup to 41.4 MPa (422 kgf/cm2). Use goggles and heavy gloves for protection during operation.
7-29
MAINTENANCE IMPORTANT: In case the grease gun becomes inoperable, do not continuously operate it further. Damage to the motor or a risk of fire may result. When a battery pack is not in use, store the battery pack keeping away from a metallic product such as a paper clip, coin, key, nail, or screw. Short circuit of the battery may create sparks leading to hazards such as burns, or fires. Always be sure to use the attached battery pack. Using a battery pack other than the attached one may cause a risk of fire.
7-30
MAINTENANCE Electric Grease Gun Specifications Operating voltage
12 V
Maximum operating pressure
41.4 MPa (422 kgf/cm2)
Grease cartridge capacity
411 cc
Operating temperature range
-18 to 50 ° C
Operating current (at pressure 6.9 MPa (70 kgf/cm2) 4 A Grease
Consistency: 2 or less
Grease delivery flow (at pressure 6.9 MPa (70 kgf/cm2)) 194 cc/minute Weight
3.76 kg
Attachments Battery pack Output voltage
12 V
Capacity
1300 mAh
Charger Charge time
1 hour
Output voltage (at1.7 A)
14.5 V
Input voltage (at 350 mA)
100 V, 50 Hz
7-31
MAINTENANCE Components Name 2
1- Switch 2- Motor assembly 3- Nozzle (CNP-2) 4- Cap
1
5- Grease cartridge 3
6- Grease cartridge cylinder 7- Chain (Lever)
6
8- Battery pack 9- Battery charger 10- Code 11- Plug
8
12- Band
7
13- Holding bracket
M1U1-07-115
12
13
10 9 11
M1U1-07-112
5
4
7-32
M16J-07-043
MAINTENANCE Battery Charger Operation Charging the Battery Pack General Before using an electric grease gun for the first time, charge the battery pack. (for approx. 12 hours) Refer to the descriptions on "Install/remove Battery Pack" for installing the battery pack to the electric grease gun. When the battery pack is almost discharged, the battery performance sharply drops. In case greasing becomes difficult, it indicates the time to recharge the battery pack. If the battery is recharged before this condition is reached, the total work life of the battery pack is reduced.
f NOTE: The battery pack temperature will increase during
or immediately after operation. Do not recharge the battery pack soon after operation. The battery pack may not be fully recharged. Recharge the battery pack only after the battery pack temperature is approximately lowered to room temperature.
CAUTION: Do not plug the vent holes at the top and dbottom of the battery charger. When the atmospheric temperature is below 0 °C or above 40 °C , do not charge the battery pack.
7-33
MAINTENANCE Normal Charging Method After checking that the electric source voltage meets the voltage shown on the battery charger specification plate, connect the battery charger to the electric source. Conduct the first battery charge for 12 hours before using the battery pack. Install the battery pack in the battery charger. As long as the red light is kept ON, it indicates that the battery pack is being charged. When the red light goes OFF and the green light comes ON, charging of the battery pack is complete. As long as the green light is ON, the battery charger is kept operated in the trickle charging mode. The trickle charging mode is maintained until the battery is used. Disconnect the plug from the electric source after using the battery charger.
f NOTE: Trickle charge means auto-maintenance charge
operation to compensate the self-discharge of the battery pack.
Installing/Removing Battery Pack Removing Battery Pack Depress 2 battery release buttons on each side of the battery pack and pull the battery back out of the electric grease gun. Installing Battery Pack After aligning the battery pack with the specified location on the electric grease gun handle, push the battery pack into the handle until it locks in place. Power Source Supply the power to the battery charger through the lighter receptacle with the output of 12 V or 24 V
7-34
MAINTENANCE IMPORTANT: Do not use the attached battery charger except for charging the attached battery pack. If a battery other than the attached one is charged personal injury and damage may result due to explosion. Never attempt to charge the attached battery pack by a battery charger other than attached one under any circumstances. Prevent the battery charger from being exposed to rain, snow or frost. Do not abuse the cord. Never carry the battery charger with the cord. Take care not to break the cord by pulling it from the receptacle. When disconnecting the battery charger, pull on the plug. Do not pull the cord. Immediately replace the damaged or worn power cord and the damaged relief valve. Do not operate the battery charger with a damaged cord or plug connected. Never attempt to repair the power cord. Do not disassemble the battery charger and/or battery pack. Risk of electric shock or fire may result if incorrectly reassembled. Do not incinerate the battery pack. It can explode in a fire. Never attempt to charge any other cordless tool or battery pack with this battery charger. Never short-circuit between the battery terminals Damage and/or fires may result due to effect of very high temperature. Properly dispose the expended battery pack. The battery pack is a chargeable nickel-cadmium battery. This type of battery is required to be recycled or disposed of in a proper method. Drop off the expended battery pack at your local replacement battery retailer or your recycling center. Do not store the battery charger and/or battery pack in locations where the atmospheric temperature may reach or exceed more than 50 °C. The battery pack will deteriorate.
7-35
MAINTENANCE Preparation for Using Electric Grease Gun 2
Installing grease cartridge IMPORTANT: Take care not to allow sand and/or dust to mix in grease when installing grease cartridge (5). 1. Turn to remove grease cartridge cylinder (6) from motor assembly (2). 2. Fully pull out chain (7) from grease cartridge cylinder (6). Attach chain (7) to a notch on the bottom of grease cartridge cylinder (6).
6
3. After removing cap (4) from grease cartridge (5), install grease cartridge (5) to the screw threads on motor assembly (2). IMPORTANT: Be alert that if grease cartridge (5) is diagonally or forcibly screwed in, damage to the screw threads may result so that the grease cartridge may not be installed to motor assembly (2).
7 M1U1-07-115
4. Screw grease cartridge cylinder (6) in the original position on motor assembly (2). Detach chain (7) from the notch.
6
7
M16J-07-042
5
4
7-36
M16J-07-043
MAINTENANCE Greasing Method IMPORTANT: When lubricating a closed space with grease, the motor rotation becomes slow as soon as grease is sufficiently filled in the lubrication space End greasing by releasing switch (1). If greasing is continued further, burning of the motor may result. 1
1. Drive the motor by pulling switch (1). Grease is discharged from the tip of nozzle (3).
3
f NOTE: When the grease gun is first used, it takes some time before discharging grease until air is bled from the motor assembly.
2. After cleanly wiping the tips of the grease fitting through which grease is added and gun nozzle (3), press the tip of nozzle (3) to chuck the grease fitting. 3. Pull switch (1) to discharge grease.
When grease is normally added, old grease is discharged through the clearance around the grease fitting.
4. After completing greasing, allow the inner pressure to release from the grease fitting by tilting nozzle (3) before disconnecting the tip of nozzle (3) from the grease fitting.
Certain amount of grease escapes at this time.
M1U1-07-115
3 Grease Fitting
f NOTE: If the motor rotation becomes very slow or stops during greasing, immediately release switch (1). The electric grease gun is a high speed type so that slight amount of grease may escape from the plunger. This is not a fault.
M16J-07-045
3 Grease Fitting M16J-07-046
7-37
MAINTENANCE After Using Grease Gun IMPORTANT: Securely fasten the single battery charger or the battery charger with the battery pack installed to the holding bracket with a band attached to the holding bracket so that the battery charger and/or the battery pack does not come off the bracket. Failure to do so may cause the battery pack and/or battery charger to come off the holding bracket, possibly resulting in damage to the battery pack and/or battery charger.
M1U1-07-061
M1U1-07-062
M1U1-07-063
7-38
MAINTENANCE Lubricator (Optional) 8
Greasing Method 1. Turn power switch (8) ON to activate pump (1). Grease is sucked up and supplied to high-pressure grease gun (3).
2
IMPORTANT: When pump (1) 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.
1
M111-07-011
3
M111-07-012
7-39
MAINTENANCE 2. Get high-pressure grease gun (3) and pay out the hose from hose reel (4) to the length required.
1
8
3. Press hydro-chuck (5) protruding from high-pressure grease gun (3) into a grease fitting and pull the lever to discharge grease. 4. Release the lever when greasing is complete; grease discharge will stop. 5. When detaching hydro-chuck (5) from grease fitting (7), grease fitting (7) tip may break unless a special care, is taken, as follows: 6. Tilt nozzle (6) a little so as to release the connecting pressure applied to hydro-chuck (5). Slowly detach hydro-chuck (5) from grease fitting (7).
5
7. 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.
6
3
f 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.
4 M111-07-012
5
7
M111-07-013
7-40
MAINTENANCE Grease Container Replacement
1
When the grease container becomes empty, follow the procedure below to replace it. IMPORTANT: When replacing grease container (4), be sure that no sand or debris sticks to suction tube (5) or to follower plate (3). If foreign matter, such as sand, gets into grease, damage to pump (1) and to parts being lubricated will result. If follower plate (3) is not correctly positioned inside the container, pump (1) may not suck grease, even with grease remaining in the container. Reposition the plate correctly if this happens.
7
2 6 3 5 4
M111-07-014
7-41
MAINTENANCE 1. Loosen wing bolts (2) located on pail cover (7). Remove pail cover (7) and follower plate (3) from empty grease container (4).
1
2. Replace grease container (4) with new one. 3. Place follower plate (3) flat on the new grease container (4). Using both hands, press follower plate (3) down while moving both hands back and forth along the periphery of the container inside, as illustrated. Apply grease to the back of follower plate (3) to fill concaved sections; this will prevent air from mixing into the grease contents. 4. Press the follower plate until grease comes out of seal packing (6) hole.
7
2 6 3
5. Slowly insert suction tube (5) into the center hole of follower plate (3).
5
IMPORTANT: Be careful not to damage seal packing (6) by the end of suction tube (5) when inserting it.
4
M111-07-014
6. Be sure that pail cover (7) correctly settles on the container. Equally tighten each wing bolt (2) to pail cover (7) to securely attach the pump assembly onto grease container (4). 7. After replacing grease container (4), insert the sway lock bracket attached on pail cover (7) into the bracket in the lubricator box.
3
4
M111-07-087
7
Grease Container M1JB-07-055
7-42
MAINTENANCE B. Engine
2
Check Engine Oil Level --- check daily Check oil level before starting the engine. The oil level should be between the upper and lower marks on dipstick (1). The oil level should be between the upper and lower marks on dipstick (1). If necessary, add the recommended engine oil via oil filler (2). Recheck oil level after adding the oil.
ZX470-5 class
1 M16J-07-006
1
2
ZX870-5 class
MJAC-07-046
1
Max. Min. M178-07-011
7-43
MAINTENANCE 2
Change Engine Oil, Replace Engine Oil Filter --- every 500 hours
d CAUTION: Immediately after the machine was operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Do not spill oil while changing oil. Wipe off any spilled oil. Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. ZX470-5 class
1
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
M16J-07-006
2. Arrange 60 liter capacity container to receive the drain oil. 3. Remove oil filler cap (2). 4. Ensure that drain cock (4) of the engine oil pan is closed. Remove plug (3) of the engine oil drain block. 5. Slowly open drain cock (4) of the engine oil pan to drain engine oil.
Engine Oil Drain Plug
6. After all oil has been drained, inspect the cloth for any debris such as small pieces of metal.
MJAC-07-042 Close
Close drain cock (4). Install drain plug (3) to the original position. (to the page 7-46) Open
4 MJAC-07-043 Opening/Closing Drain Cock (The illustration shows closing condition.)
4 Oil Pan
3
Clean Cloth
Container
7-44
MJAC-07-044
MAINTENANCE ZX870-5 class 1
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
2
2. Arrange a container to receive the drain oil. Capacity : Approx. 60 L 3. Remove oil filler cap (2). 4. Remove cap (4) from oil pan drain valve (3). Install drainer (5) to drain valve (3). Screw drainer (5) into drain valve (3). Drain valve (3) will be opened to drain oil. IMPORTANT: Install drainer (5) to the drain valve slowly. Oil may exhaust in large quantities when suddenly tightened. 5. After all oil has been drained, inspect the cloth for any debris such as small pieces of metal.
ZX870-5 class
MJAC-07-046
3, 4
6. Remove drainer (5). Install cap (4) to drain valve (3).
M1U1-07-045
5
M1U1-07-046 Oil
Oil
Oil Pan
Oil Pan
3 Clean Cloth Container Screw
5 Oil
M104-07-010
7-45
M1U1-07-002
MAINTENANCE 7. Remove the filter cartridges of engine oil filter (6) by turning it counterclockwise with the filter wrench. 8. Pour clean oil in the new cartridge, not letting it overflow. Apply a thin film of clean oil on the gasket (O-ring) of the new filter. Install new filter. Turn the filter cartridge clockwise by hand until the gasket touches the contact area. 9. Tighten the filter 3/4 to 1 turn more using the filter wrench. Be careful not to overly tighten the cartridge element. Deformation of the cartridge may result. 10. Fill the engine with recommended oil through the oil filler.
6 ZX470-5 class
MJAC-07-017
6 ZX870-5 class
MJAC-07-034
11. Check that the oil level is between the minimum and maximum level scales on the dipstick. Then, start the engine. 12. After starting the engine, check no oil is leaking from the sealing surface. 13. After running the engine at slow idle speed for approx. 5 minutes, stop the engine. Then, check the oil level 15 minutes later. Add or drain oil if necessary and recheck the oil level. The oil level should be between the upper and lower marks on the oil level gauge. IMPORTANT: When filling new oil, take care not to allow foreign matter to enter the engine. Do not re-use cartridge element (6).
7-46
MAINTENANCE C. Transmission
2
Pump Transmission (ZX870-5 class)
1
Check Oil Level --- every 250 hours 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. When the oil level is correct, it can be seen between marks on level gauge (1). 3. If necessary, remove filler plug (2) and add oil. 4. Recheck oil level after adding the oil.
MJAC-07-047
7-47
MAINTENANCE Change Gear Oil --- every 1000 hours
5
Clean Air Breather--- every 1000 hours
d
1
WARNING: Oil may be hot just after operation. Wait for the engine to cool before starting any maintenance work.
4
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. Remove filler plug (1). 3. Remove drain plug (2) located at left rear of the frame. Open drain cock (3) to drain oil. Drain oil into 10 liter capacity container covered by clean cloth. After all oil has been drained, inspect the cloth for any debris such as small pieces of metal.
MJAC-07-047
4. Close drain cock (3). Install drain plug (2). 5. Refill oil though filler port (1). 6. Refill oil through the oil filler port of filler plug (1) until oil level is between the upper and lower marks on level gauge (4).
3 2
7. Install filler plug (1). 8. Remove air breather (5). Clean the air breather.
After cleaning air breather (5), wrap a seal tape around the air breather. M1JB-07-044
Tightening torque Oil Filler Plug
140 N·m (14 kgf·m)
Air Breather
15 N·m (1.5 kgf·m)
Specified Range
4
M16J-07-048
7-48
MAINTENANCE Swing Reduction Gear
1
Check Oil Level --- every 250 hours 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. When the oil level is correct, it can be seen between marks on level gauge (1). 3. If necessary, remove filler plug (2) and add oil. 4. Recheck oil level after adding the oil.
2 MJAA-07-030
ZX470-5 class 1
2
Specified Range
ZX870-5 class
MJAA-07-099
1
M16J-07-048
7-49
MAINTENANCE Change Gear Oil --- every 1000 hours
1
WARNING: Oil may be hot just after operation. Wait dfor the engine to cool before starting any maintenance work.
3
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. Remove drain plug (4) mounted at the tip of the drain hose under the swing reduction gear. Open drain cock (3) to drain gear oil. 3
3. Close drain cock (3). Install drain plug (4).
2
4. Remove filler port cap (2). Refill oil until oil level is in the specified range of level gauge (1). 5. Recheck oil level after adding the oil. Model ZX470-5 class ZX870-5 class
MJAA-07-030
ZX470-5 class
1
Oil Capacity 6.5 L×2 15.7 L×2
2
ZX870-5 class
4
MJAA-07-099
MJAA-07-032
ZX470-5 class
3
4 ZX870-5 class
7-50
M1JB-07-002
MAINTENANCE Travel Reduction Gear Check Oil Level --- every 250 hours
d WARNING: Immediately after the machine was operated, all parts of the travel device are hot. Wait for the engine to cool before starting any maintenance work. There may be pressure accumulated inside of the travel device. Remove the plug only after releasing pressure by slowly loosening the air bleed plug two to three turns. Failure to do so may cause the plug to fly off or the gear oil to gush out, possibly resulting in personal injury. Keep body and face away from the air release plug.
Air Release Plug (Oil Supply Plug)
Horizontal Oil Level
Oil Level Check Plug
1. Park the machine on a solid level surface. 2. Rotate the travel motor until plug (1) (air release and oil supply) is in the top position as shown in figure right. 3. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 4. Wait for the gear oil t cool. Slowly loosen plug (1) to release air pressure.
Drain Plug MDAA-07-047
1
5. Remove plugs (1 and 2). When the oil level is correct, the gear oil will flows out of the tapped hole of plug (2).
2
6. If necessary, refill oil until the gear oil flows out of the tapped hole of plug (2). 7. Clean plugs (1) and (2). Wrap the threads of oil level check plug (2) and air release plug (1) with sealing-type tape. Reinstall the plugs. Tighten the plug.
3
M157-07-170
Tightening Torque: 70 N·m (7.0 kgf·m)
8. Check opposite side of the travel device for oil level.
7-51
MAINTENANCE Change Gear Oil --- every 2000 hours
d WARNING: Immediately after the machine was operated, all parts of the travel device are hot. Wait for the engine to cool before starting any maintenance work. There may be pressure accumulated inside of the travel device. Remove the plug only after releasing pressure by slowly loosening the air bleed plug two to three turns. Failure to do so may cause the plug to fly off or the gear oil to gush out, possibly resulting in personal injury. Keep body and face away from the air release plug. 1. Park the machine on a solid level surface. 2. Rotate the travel motor until plug (1) (air release and oil supply) is in the top position as shown in figure right. 3. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 4. Wait for the gear oil t cool. Slowly loosen air bleed plug (1) to release air pressure. Tighten air bleed plug (1). 5. Remove drain plug (3) and plug (1), in that order, to drain oil. 6. Clean drain plug (3). Wrap the threads of drain plug (3) with sealing-type tape. Reinstall and tighten the plug.
Tightening Torque: 70 N·m (7.0 kgf·m)
7. Remove oil level check plug (2). 8. Refill oil until oil flows out of the tapped hole of plug (2). 9. Clean plugs (1) and (2). Wrap the threads of oil level check plug (2) and air release plug (1) with sealing-type tape. Reinstall the plugs. Tighten the plug.
Tightening Torque: 70 N·m (7.0 kgf·m)
10. Perform steps 5 to 13 for the opposite travel device.
7-52
1
2
3
M157-07-170
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment IMPORTANT: Never adjust parts of engine fuel system or hydraulic equipment. CAUTION: When checking and/or servicing the dhydraulic components, pay special attention to the following points. 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 Before checking and/or servicing the hydraulic system, be sure to release the residual pressure from the cylinder circuits of the boom, arm and the bucket, swing piping and pilot piping. This machine provides the accumulator in order to deliver pressure oil to the operation control circuit for a while (approx. 10 seconds) after the engine stops. 3.2 Bleed air from the hydraulic oil tank to release internal pressure. 3.3 Immediately after operation, all hydraulic components and hydraulic oil or lubricants are hot and highly pressurized. Begin inspection and/or maintenance work only after the machine has cooled down.
Servicing heated and pressurized hydraulic components may cause plugs, screws and/or oil to fly off or escape suddenly, possibly resulting in personal injury. Hydraulic components may be pressurized even when cooled.
Keep body parts and face away from the front of plugs or screws when removing them.
3.4 Even after air pressure in the hydraulic oil tank is released, when the machine is parking on a slope, the oil pressure in the travel motor and the swing motor circuits are maintained at high pressure as the reaction force of the machine weight is constantly applied to the travel motor. Never check and/or service the machine parking on a slope.
7-53
MAINTENANCE IMPORTANT: When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them. Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them. Only use O-rings that are free of damage or defects. Be careful not to damage the mounting surface. Do not allow high pressure hoses to twist when connecting them. The life of twisted hoses will be shortened considerably. IMPORTANT: Do not use hydraulic oils other than those listed in the table "Brand names of recommended hydraulic oil". When adding hydraulic oil, always use the same brand of oil; do not mix brands of oil. When using another manufacturer's hydraulic oil, be sure to change the full amount. The new machine is filled with hydraulic oil of NEW LANDY HN (change interval: every 4000 hours). When adding or changing the hydraulic oil, continue to use the NEW LANDY HN. IMPORTANT: Never run the engine without oil in the hydraulic oil tank.
7-54
MAINTENANCE Change Hydraulic Oil and Replace Full-Flow Filter Element Hydraulic breaker operation subjects the hydraulic system to become contaminated faster and to quickly deteriorate the hydraulic oil. Failure to adhere to proper maintenance intervals may result in damage to the base machine and the breaker. In order to extend the service life particularly of the hydraulic pump, change the hydraulic oil and the full-flow filter element at the specified frequency given below. Check machine service hours by using the breaker hour meter. Replacement Intervals (Hours) of Hydraulic Oil and Full Flow Filter Element Attachment
Availability
Bucket
100 %
Hydraulic Breaker
100 %
Full Flow Filter Element Breaker Return Filter Element
Hydraulic Oil 2000 4000 600
1000 100
: Replacement intervals differ depending on the brand of hydraulic oil used. Refer to the Hydraulic System in the MAINTENANCE section.
When using high performance element Average Breaker Operating Availability (%)
100 90
Element Replacement Intervals
80 70 60
Changing Interval when using 2000-hour life time hydraulic oil
50
Changing Interval when using 4000-hour life time hydraulic oil
40 30 20 10 0
0
500
1000
1500
2000
2500
Changing Intervals (hours)
7-55
3000
3500
4000 MJAC-07-045
MAINTENANCE Check Hydraulic Oil Level --- daily 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. Open front left cover. Check oil level with level gauge (1) at the side of the hydraulic oil tank. When the oil level is correct, it can be seen between marks on level gauge (1).
M104-07-021
CAUTION: Hydraulic oil tank is pressurized. Push dthe air bleed button on the air breather to release air. Carefully remove the cap.
Refill oil
1
3. Push the air bleed button on the air breather to release air. Remove the cover. 4. Refill oil. Check oil level with level gauge (1). 5. Install the cover. Ensure that the filter and the rod assembly are installed in the correct position. ZX470-5 class
MJAA-07-037
1
ZX870-5 class
7-56
MJAA-07-044
MAINTENANCE Water Drain from Hydraulic Oil Tank --- every 250 hours WARNING: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Start work only after oil temperature cools, or conduct work before operating the machine in the morning.
1. Park the machine on a solid level surface and rotate the upperstructure 90° (1/4 turn).
M104-07-117
2. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
1
3. After leaving the machine without operating to cool the oil temperature, bleed air pressure from the hydraulic oil tank. CAUTION: Hydraulic oil tank is pressurized. Push air dbleed button (1) of the air breather before removing plug (2).
M1J1-07-006
4. Push air bleed valve (1) to bleed air from the hydraulic oil tank. 5. Remove plug (2) from drain cock (3) on the bottom of the hydraulic oil tank and slowly open drain valve (3) to drain water and/or sediment from the hydraulic oil tank.
3
2
7-57
M1J1-07-037
MAINTENANCE Change Hydraulic Oil --- every 4000 hours or 2000 hours Suction Filter Cleaning --- each time when hydraulic oil is changed CAUTION: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
IMPORTANT: Changing interval differs according to the brand of hydraulic oil used, kind of filter element or average attachment operating availability. (Refer to 7-48)
7-58
MAINTENANCE Change Hydraulic Oil 1. Park the machine on a solid level surface and rotate the upperstructure 90° (1/4 turn). 2. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 3. Clean top face of the hydraulic oil tank to prevent dust from entering into the hydraulic system.
d
M104-07-117
2
CAUTION: Hydraulic oil tank is pressurized. Push air bleed button (1) of the air breather before removing cover (2).
1
4. Push air bleed valve (1) to bleed air from the hydraulic oil tank. 5. Remove filler port cover (2).
Level Gauge
6. Arrange a container with the hydraulic oil capacity. Remove oil by using a suction pump.
Specified Range
The hydraulic oil tank capacity is as follows. ZX470-5 class
310 L
ZX870-5 class
500 L
M157-07-016
7. Remove plug (4) from drain cock (3) on the bottom of the hydraulic oil tank and slowly open drain cock (3) to drain remaining oil from the hydraulic oil tank.
3
2
7-59
M1J1-07-037
MAINTENANCE 1
8. Remove cover (1) and rod assembly (2). 9. Clean the inside of the hydraulic oil tank and the suction filter.
When replacing the suction filter, install new filter to rod (2) as shown in the figure.
Tightening Torque: 15 to 20 N·m (1.5 to 2 kgf·m)
4
2
10. Before installing the suction filter, check the dimension of rod assembly (2) shown in figure right. Securely insert rod assembly (2) into pipe (3).
3
11. Clean drain plug (6). Install drain plug (6). Close drain cock (5). 12. Refill hydraulic oil until the oil level is in the specified range of the level gauge. M1J1-07-060
13. Before securing cover (1) with bolts, ensure the top edge of the rod assembly (2) is completely inserted into the hole of support (4).
ZX470-5 class: 945 mm ZX870-5 class: 1220 mm
Tightening Torque: 50 N·m (5.0 kgf·m) 20 mm
14. Be sure to bleed air form the system following the procedures shown next page.
ZX470-5 class: 157 mm ZX870-5 class: 195 mm
15. Replace the element at the recommended regular intervals to keep the hydraulic oil clean and to extend the service life of the hydraulic equipment.
2 Rod Assembly
M107-07-070
Level Gauge Specified Range
M157-07-016
5
6 M1J1-07-037
7-60
MAINTENANCE Bleed Air from the Hydraulic System Engine
After changing hydraulic oil, bleed air from the hydraulic system by following the procedures below. IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started. Bleed air from the pump.
6
Bleeding Air from Pump 1. Remove air bleed plugs (6) and (7) on top of pumps. 2. Refill hydraulic oil until oil flows out of the holes of air bleed plugs (6) and (7). 3. Temporally tighten plugs (6) and (7) of each pump. Start to run the engine at slow idle speed.
Slightly loosen plug (6) or (7). Allow air to bleed from the pump through the clearance until hydraulic oil permeates around the plug.
After bleeding air, securely tighten plugs (6) and (7). Perform same procedure for the other pumps.
ZX470-5 class
4. Start to run the engine at slow idle speed. While moving all cylinders and the swing motor evenly, lightly operate the machine for 15 minutes.
M16J-07-050
6
5. Rest the bucket on the ground to resume the hydraulic oil level check position. 6. Turn the auto-idle switch OFF. 7. Stop the engine. Remove the key. 8. Be sure to place the pilot control shut-off lever to the LOCK position. 9. Stop the engine. Check the oil level. Add oil as needed. Bleeding Air from Hydraulic Circuit 1. After filling hydraulic oil, start the engine. While moving all cylinders and the swing motor evenly, lightly operate the machine for 10 to 15 minutes.
ZX870-5 class (Main Pump)
MJAA-07-100
As the air bleeding device is provided in the pilot circuit, air will be released by conducting above operation for 5 minutes.
2. Perform steps 5 to 9 of "Bleeding air from Pump" described above.
7
Engine
ZX870-5 class (Fan Pump)
7-61
M1JB-07-046
MAINTENANCE Replacement of Full-Flow Filter --- every 1000 hours WARNING: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
M104-07-021
Procedures:
8
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". CAUTION: Hydraulic oil tank is pressurized. Push air dbleed button (8) of the air breather before removing cover (2).
2. Push air bleed valve (8) to bleed air from the hydraulic oil tank.
M1J1-07-006
1
2
3. Loosen bolts (1) (6 used) to remove cover (2) and O-ring (3).
When removing cover (2), slowly remove the cover while pressing the cover downward so that spring (4) does not fly off.
4. Remove spring (4), valve (5) and element (6). 5. When installing new element (6) into the hydraulic oil tank, replace O-ring (3) with a new one at the same time.
3 4 5 6
Take extra care never to allow water or dust to enter the filter case.
6. Install cover (2) with bolts (1) (6 used).
Tightening Torque: 50 N·m (5.0 kgf·m)
7. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.
( Refer to "
Bleed Air from the Hydraulic System".)
If the machine is operated with air mixed in the hydraulic circuit, damage to the pump may result.
8. Replace element (6) at the regular interval to keep hydraulic oil clean and to extend the service life of the hydraulic components.
7-62
M111-07-040
MAINTENANCE Replace Pump Drain Filter --- every 1000 hours WARNING: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
M104-07-021
8
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". CAUTION: Hydraulic oil filter is pressurized. Push air dbleed button (8) of the air breather before removing filter (2).
2. Push air bleed valve (1) to bleed air from the hydraulic oil tank.
M1J1-07-006
3. Rotate the hexagonal section on the bottom of the drain filter cartridge type element (2) counterclockwise with a spanner to remove the filter from the filter head. 4. Apply clean hydraulic oil on the sealing section of new element (2). Lightly rotate the element clockwise by hand until the element comes in contact with the filter head. 5. Tighten the cartridge filter element further approx. 1/2 turns using the filter wrench. Be careful not to overly tighten the element. Deformation of the element may result. 6. Start the engine. Check that no hydraulic oil leaks are present.
ZX470-5 class
2
M1J1-07-010
7. Replace the element at the regular interval to keep hydraulic oil clean and to extend the service life of the hydraulic components.
2
ZX870-5 class
7-63
MJAA-07-044
MAINTENANCE Replace Pilot Oil Filter --- every 1000 hours WARNING: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
M104-07-021
1
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". CAUTION: Hydraulic oil tank is pressurized. Push air dbleed button (1) of the air breather before removing the pilot filter.
M1J1-07-006
2. Push air bleed valve (1) to bleed air from the hydraulic oil tank.
7-64
MAINTENANCE 3. Rotate the hexagonal section on the bottom of pilot filter cartridge element (3) counterclockwise by using a spanner to remove cartridge element (3) from head cover (2). 4. Clean O-ring contact surface on head cover (2).
2
5. Apply thin film of clean hydraulic oil on the gasket of new cartridge element (3). 6. Taking care not to damage, turn the cartridge element (3) clockwise by hand until the O-ring touches head cover (2). 7. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.
( Refer to "
If the machine is operated with air mixed in the hydraulic circuit, damage to the pump may result.
3
Bleed Air from the Hydraulic System".) M1U1-07-050
8. Replace the element at the recommended regular intervals to keep the hydraulic oil clean and to extend the service life of the hydraulic equipment.
7-65
ZX470-5 class
M1J1-07-009
ZX870-5 class
MJAA-07-044
MAINTENANCE Replace Air Breather Element --- every 4000 hours CAUTION: Hydraulic oil becomes hot and pressurized dduring operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
M104-07-021
Procedures: 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". CAUTION: Hydraulic oil tank is pressurized. Push the dair bleed valve of the air breather before removing the element.
2. Push the air bleed valve of the hydraulic oil tank to bleed air from the hydraulic oil tank. 3. Rotate cover (2) clockwise approx. 1/4 turns. Remove cap (1) by rotating it counterclockwise. MJAA-07-036
4. Rotate cover (2) counterclockwise and remove it. Remove element (3). 5. Install new element (3). Tighten to install cover (2) until cover (2) comes in contact with element (3). Then, further tighten the cover 1/4 turn.
1
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.
2
7. Take care never to allow water and/or contaminant to stay between cover (2) and body (4) (air breathing port).
3
8. Replace element (3) at the regular interval to keep hydraulic oil clean and to extend the service life of the hydraulic components. 4
M1G6-07-001
7-66
MAINTENANCE Check Hoses and Lines --- daily --- every 250 hours
d WARNING: Hydraulic oil and lubricant leaks can lead to fire that may result in serious injury. 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. Escaping oil under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for oil 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.
SA-031
Tighten, repair or replace any missing, loose or damaged clamps, hoses and lines. Do not bend or strike high-pressure lines. Never install bent or damaged hoses or lines. According to the check points shown below, check hoses and lines for oil leaks and damage. If any abnormality is found, replace or retighten as instructed in the table.
SA-292
SA-044
Hose Interval (hours) Daily Check
Check Points
Abnormalities
Remedies
Hose covers
Leak (1)
Replace
Hose ends
Leak (2)
Replace
Fittings
Leak (3)
Retighten or replace hose or O-ring
3
2 1 2 3 M137-07-008
3
2 1
2 3
M115-07-145
7-67
MAINTENANCE Interval (hours) Every 250 hours
Check Points
Abnormalities
4
Remedies
5
Hose covers
Damage or leak (4)
Replace
Hose ends
Damage or leak (5)
Replace
Hose covers
Exposed reinforcement (6)
Replace
Hose covers
Crack or blister (7)
Replace
Hose
Bend (8), Collapse (9)
Replace
Hose ends and Fittings
Deformation or corrosion (10)
Replace
M115-07-146
7 6
M115-07-147
8
M115-07-148
9
10
Lines
M115-07-149
Interval (hours) Daily Check
Check Points
Abnormalities
13
Contact surfaces of flange joints Leak (11)
Replace
Bolts
Retighten or replace O-ring
Loose or leak (11)
Welded surfaces on flange joints Leak (12) Every 250 hours
Remedies
Flange joint neck
Replace
Welded surfaces on flange joints Crack (12)
Replace
Clamps
Replace or retighten
Missing or deformation Loose bolts
7-68
11
M137-07-001
Replace
Crack (13)
12
12 13
M137-07-007
MAINTENANCE Oil Cooler Interval (hours) Every 250 hours
Check Points
Abnormalities
Remedies
Coupling
Leak (14)
Retighten or replace
Oil Cooler
Leak (15)
Replace
15
MJAC-07-020
ZX470-5 class 14 14
14 15
14
14 ZX870-5 class
7-69
MJAC-07-035
MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) O-ring (1) is used on the sealing surfaces of adapter (2) to prevent oil leakage.
2
1
4
5
Precautions for Use 1. Replace O-ring (1) with a new one when assembling fittings. 2. Check that O-ring (1) is properly fitted in O-ring groove (3). Tighten union (4).
Tightening union (4) with O-ring (1) out of the groove may damage O-ring (1) and cause oil leak.
3. When assembling fittings, take care not to make a dent on O-ring groove (3) of adaptor (2) and sealing surface (6) on hose (5) or valve side. Failure to do so may result in damage to O-ring (1) leading to oil leak. 4. If oil leaks from a loose connection of union (4), do not tighten fitting (2). Open the connection, replace O-ring (1) with new one and check for correct O-ring position before tightening the connection. Tightening torque Tighten fittings to the torque values shown below. ±10 % Wrench size (mm) N·m Tightening torque (kgf·m)
27 32 36 41, 46 50 95 140 180 210 260 (9.5) (14.0) (18.0) (21.0) (26.0)
7-70
3
6
M104-07-033
MAINTENANCE Metal Face Seal Fittings Metal joint is used in small diameter joint which seals pressure oil by metal flare (10) and metal flare sheet (9). 1. Check flare (10) and flare sheet (8) for contamination and scratches.
7
9
8
10
5
2. Tighten adapter (7) by hand. 3. Tighten adapter (7) and nut (8) to the torque values shown below. Do not allow hoses to twist when tightening the adapter.
M202-07-051
Tightening torque Tighten fittings to the torque values shown below. Wrench size (mm) N·m (kgf·m)
Tightening torque
17 25 (2.5)
19 30 (3.0)
22 40 (4.0)
27 80 (8.0)
11
Bent Tube Tighten bent tube (11) mounted on the signal control valve to the torque values shown below. Wrench size (mm) N·m (kgf·m)
Tightening torque
17, 19 35 (3.5) To Signal Control Valve
M1U1-07-043
7-71
MAINTENANCE E. Fuel System
d CAUTION: Beware of fire. Fuel is flammable. Keep fuel away from fire hazards. Recommended Fuel Use only DIESEL FUEL (JIS K-2204) (ASTM 2-D). Kerosene must NOT be used. Besides, using bad quality fuel, drainage agent, fuel additives, gasoline, kerosene or alcohol refueled or mixed with specified fuel may deteriorate performance of fuel filters and cause sliding problem at lubricated contacts in the injector. It also affects the engine parts, leading to malfunction.
7-72
MAINTENANCE Refueling CAUTION: Take extra care when handling fuel. Stop dthe engine when refilling fuel. Keep fire away from
1
the machine when refilling fuel or doing maintenance work of fuel system. IMPORTANT: Take care not to allow dirt and/or water to enter the fuel tank. Wipe off any spilled fuel. 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
MDAA-01-001
2. Check oil level with level gauge (1).
2
Add fuel if necessary.
3. To avoid condensation, fill the tank at the end of each day's operation. Tank capacity is as follows. Model ZX470-5 class ZX870-5 class
Tank Capacity 705 L 1110 L
3
Do not fill the tank more than specified. Stop filling when fuel becomes visible in fuel level gauge (3).
4. Immediately after fueling, install and lock filler cap (2) to prevent vandalism and loss.
MJAA-07-102
ZX470-5 class 2 3
ZX870-5 class
7-73
MJAA-07-045
MAINTENANCE Drain Fuel Tank Sump --- daily Before starting operation, open drain valve (4) to drain water and/or sediment from the fuel tank. 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. Place 0.5 liter or larger capacity container under the drain hose to collect drain. 3. Open drain valve (4) to drain water and/or sediment from the fuel tank.
ZX470-5 class
4. After draining water, securely tighten drain valve (4).
4 ZX870-5 class
7-74
4
MJAA-07-101
MJAA-07-046
MAINTENANCE Check Water Separator --- every 50 hours 3
Water separator (3) is a device designed to separate water from the fuel. There is a float inside the case which buoys when water accumulates. When the float rises to water draining level (5) indicated on the outer surface of the case, drain water. IMPORTANT: If high water content fuel is used, check float level in the shorter interval and drain water. Drain Procedures 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
MJAC-07-025
ZX470-5 class
3
2. Check that the fuel cock at the vicinity of the fuel prefilter is opened. 3. Place 0.5 liter or larger capacity container under the drain hose to collect drain. 4. Loosen drain plug (6) at lower part of water separator (3) to drain water. If it is difficult to drain, loosen plug (4) on the top of water separator (3). 5. After draining water, securely tighten drain plugs (4) and (6). 6. Bleed Air from the Fuel System
After draining water from the water separator, bleed air from the fuel supply system. (Refer to "Bleed Air from the Fuel System" on the next page.)
MJAC-07-040
ZX870-5 class
4
5
6
M110-07-031
7-75
MAINTENANCE Bleed Air from the Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After running the fuel tank dry, draining water and sediment from the water separator or replacing the fuel filter element, be sure to bleed air from the fuel system. Main Points to Bleed Air 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
1
2. Check that the fuel cock at the vicinity of the fuel prefilter is opened. 3. Ensure that plug (1) at the top of water separator (3) and drain plug (4) are closed.
3
4. Loosen joint bolt (2) at the outlet port of the fuel filter. Move feed pump (5) up and down until no air bubble is mixed in the fuel.
4
f NOTE: Do not loosen plug (1) at the top of water separator (3) when bleeding air.
M110-07-031
If plug (1) is loosened, air bleeding cannot be done. 5. Close joint bolt (2) at the outlet port of the fuel filter.
Move feed pump (5) up and down until it becomes heavy, then, tighten joint bolt (2).
2
6. Start the engine. Check the fuel supply system for fuel leaks.
5
M111-07-046
7-76
MAINTENANCE Replace Fuel Main Filter --- every 500 hours IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel filter element and the prefilter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers' elements are excluded from Hitachi Warranty Policy.
1
ZX470-5 class
Procedures:
M111-07-091
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance". 2. Close the fuel cock at the vicinity of the fuel pre-filter. 3. Remove main filter (1) with a tool.
For safety and in order not to pollute the ground with fuel, be sure to drain fuel on a container.
1
4. Apply thin film of clean hydraulic oil on the gasket of new main filter (1). 5. Lightly rotate main filter (1) by hand until the seal surface comes in contact with the gasket. ZX870-5 class
6. Tighten the filter 1/2 to 3/4 turn more using a filter wrench.
Be careful not to overly tighten main filter (1). Deformation of the filter may result.
7. Bleed Air from the Fuel System
After replacing the fuel filter element, bleed air from the fuel supply system.
( Refer to "
Bleed Air from the Hydraulic System".)
7-77
MJAC-07-040
MAINTENANCE Replace Fuel Pre-Filter --- every 500 hours or when fuel filter clogging lamp is lit
Pre-Filter
IMPORTANT: Be sure to use only genuine Hitachi elements for the main fuel filter element and the prefilter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life. Please be noted that all engine failures caused by using other manufacturers' elements are excluded from Hitachi Warranty Policy. ZX470-5 class
MJAC-07-021 Pre-Filter
ZX870-5 class
7-78
MJAC-07-036
MAINTENANCE Procedures: 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
2 3
2. Close cock (3) under the fuel pre-filter. 3. Remove cartridge filter (2) with a tool. For safety and in order not to pollute the ground with fuel, be sure to drain fuel on a container. 4. Apply thin film of clean hydraulic oil on the gasket of new cartridge filter (2). 5. Lightly rotate cartridge filter (2) by hand until the seal surface comes in contact with the gasket. 6. Tighten the filter 1/2 to 3/4 turn more using a filter wrench. Be careful not to overly tighten cartridge filter (2). Deformation of the filter may result.
ZX470-5 class
MJAC-07-021
2
3
7. After replacing the cartridge filter, open cock (3). 8. Bleed Air from the Fuel System
After replacing the fuel filter element, bleed air from the fuel supply system.
( Refer to "
Bleed Air from the Hydraulic System".)
ZX870-5 class
7-79
MJAC-07-036
MAINTENANCE Clean Feed Pump Strainer --- every 1000 hours
3
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
1
2. Close the fuel cock at the vicinity of the fuel pre-filter. 3. Remove strainer (3) mounted on joint bolt (1) at fuel supply side of feed pump (2). Wash removed strainer (3) with light oil.
M157-07-191
4. After washing strainer (3), install strainer (3) to joint bolt (1). Install joint bolt (1) to feed pump (2). 5. Close the fuel cock at the vicinity of the fuel pre-filter. 6. Bleed Air from the Fuel System
After washing the feed pump strainer, bleed air from the fuel supply system.
( Refer to "
2
Bleed Air from the Hydraulic System".) 1
M111-07-090
7-80
MAINTENANCE Check Fuel Hoses ---daily --- every 250 hours Fuel leaks can lead to fires that may result dinCAUTION: serious injury. Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that rub against each other, and any fuel leaks. Repair or replace any loose or damaged hoses. Never reinstall bent or damaged hoses. According to the check points shown below, check hoses for oil leaks and damage. If any abnormality is found, replace or retighten as instructed in the table. Hose Interval (hours) Daily Check Every 250 hours
Check Points
Abnormalities
Remedies
Hose ends
Leak (1)
Retighten or replace
Hose covers
Wear, crack (2)
Replace
Hose covers
Crack (3)
Replace
Hose ends
Crack (4)
Replace
Hose
Bend (5), Collapse (6)
Replace
Hose fittings
Corrosion (7)
Replace
1
2
1 M137-07-003
3
4 M137-07-004
5
M137-07-005
6
7 M137-07-006
7-81
MAINTENANCE F. Air Cleaner
2
Clean Air Cleaner Element --- every 250 hours or when the restriction indicator comes ON Replace Air Cleaner Outer/Inner Element --- after cleaning 6 times or after one year ZX470-5 class Clean and Replace Air Cleaner Outer/Inner Element Stop the engine before servicing the elements (outer (1), inner (4)). 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
MJAC-07-011
3
1
2. Remove clamp (3) and cover (2). 3. Remove outer element (1). At this time, do not remove inner element (4). WARNING: When using compressed air pressure d(less than 0.2 MPa (2 kgf/cm2)), wear safety glasses or goggles.
IMPORTANT: Do not hit or clash outer element (1) against other object to clean the element. Do not remove inner element (4). Also, do not reuse inner element (4). 4. Allow compressed air pressure [less than 0.2 MPa (2 kgf/ cm2)] to blow out of the inside of outer element (1) to clean the element. `After cleaning is complete, be sure to check outer element (1) for any damage. If any damage is found, replace the element with new one.
5
MJAC-07-012
4
5. In case the air cleaner restriction indicator lights soon after cleaning outer element (1) even if the cleaning times are less than 6 times, replace both outer and inner elements with new ones. Replace inner element (4) at the same time. IMPORTANT: Do not install element (1) and/or the cover forcibly when installing the clamps. Failure to do so may result in deformation of clamps (3), element, and/ or cover.
f NOTE: Install outer element (1) while fitting it with the grove of body (5). If the groove has not fit when installing, it will make difficult when removing the outer element.
7-82
MJAC-07-013
MAINTENANCE ZX870-5 class Clean and Replace Air Cleaner Outer/Inner Element Stop the engine before servicing the elements (outer (1), inner (4)). 1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
3
2. Remove mounting nut (3) and cover (2). 3. Remove outer element (1). At this time, do not remove inner element (4). WARNING: When using compressed air pressure d(less than 0.2 MPa (2 kgf/cm2)), wear safety glasses or goggles.
IMPORTANT: Do not hit or clash outer element (1) against other object to clean the element. Do not remove inner element (4). Also, do not reuse inner element (4). 4. Allow compressed air pressure [less than 0.2 MPa (2 kgf/ cm2)] to blow out of the inside of outer element (1) to clean the element. After cleaning is complete, be sure to check outer element (1) for any damage. If any damage is found, replace the element with new one. 5. In case the air cleaner restriction indicator lights soon after cleaning outer element (1) even if the cleaning times are less than 6 times, replace both outer and inner elements with new ones. Replace inner element (4) at the same time.
2
MJAC-07-029
1
MJAC-07-030
f NOTE: Install outer element (3) while fitting it with the grove of body (5). If the groove has not fit when installing, it will make difficult when removing the outer element.
4 5
MJAC-07-031
7-83
MAINTENANCE G. Cooling System Coolant IMPORTANT: Use fresh water or normal tap water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 60 %.
Antifreeze Mixing Ratio Air Temperature [°C]
Mixing Ratio [%]
-1 -15 -20 -25 -30 -50
30 35 40 45 50 60
ZX470-5 class Antifreeze [L] 18.3 21.4 24.4 27.5 30.5 36.6
ZX870-5 class
Soft water [L] 42.7 39.6 36.6 33.5 30.5 24.4
Precautions for handling antifreeze
d CAUTION:
Antifreeze is poisonous.
Antifreeze is poisonous; if ingested, it can cause serious injury or death. Induce vomiting and get emergency medical attention immediately. If antifreeze is accidentally splashed into eyes, flush with water for 10 to 15 minutes and get emergency medical attention. 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. Use attention to fire hazards. LLC is specified as a dangerous substance in the fire protection law. When disposing of LLC, be sure to comply with all local regulations. When storing or disposing of antifreeze, be sure to comply with all local regulations.
7-84
Antifreeze [L] 33.6 39.2 44.8 50.4 56.0 67.2
Soft water [L] 78.4 72.8 67.2 61.6 56.0 44.8
MAINTENANCE Check Coolant Level --- daily
1
With the engine cold, the coolant level must be between the FULL and LOW marks on coolant reservoir (2). If the coolant level is below the low mark, add coolant to coolant reservoir (2). CAUTION: Do not remove cap (1) until the coolant temperature in the radiator becomes cool. Hot steam may spout out, possibly causing severe burns. After the coolant temperature has cooled, slowly loosen cap (1) to release the inside air pressure before removing cap (1).
d
MJAC-07-037
If coolant reservoir (2) is empty, add coolant to the radiator and then to coolant reservoir (2).
2
FULL
LOW
ZX470-5 class
MJAC-07-022
2
FULL LOW
ZX870-5 class
7-85
MJAC-07-038
MAINTENANCE Change Coolant --- twice a year (in spring and autumn)
f NOTE: When genuine Hitachi Long-Life Coolant is used, change interval is once every two years (in autumn every other year) or every 4000 hours whichever comes first.
CAUTION: Do not loosen the radiator cap until the dsystem has cooled. Hot steam may spout out, possibly causing severe burns. Loosen the cap slowly to the stop. Release all pressure before removing the cap.
Procedure: SA-039
1. Park the machine by following the instructions on page 7-8 "Preparations for Inspection and Maintenance".
1
2. Remove the under cover. Remove drain cock cover (1) of the radiator for ZX870-5 class. 3. Place a suitable container under drain cock (2) of the radiator and drain cock (3) of the engine water jacket to receive drain coolant. 4. Remove the radiator cap. Open drain cocks (2) and (3) to allow the coolant to drain completely. Remove impurities such as scale at the same time.
M1J7-07-018
2
M1J7-07-022
3
M1J1-07-044
7-86
MAINTENANCE 5. Close drain cocks (2) and (3) and fill the cooler with clean soft water or tap water with the radiator cleaner.
Coolant Capacity ZX470-5 class ZX870-5 class
52 L 112 L
5
6. Start the engine and run at a speed slightly higher than slow idle; when the needle of the temperature gauge reaches the green zone (5), run the engine for about ten more minutes. 7. Stop the engine and open radiator drain cock (2). Flush out the cooling system with tap water, until draining water is clear. This helps remove rust and sediment.
MDAA-01-001
8. Close drain cocks (2) and (3). Fill the radiator with soft water containing fewer impurities or tap water up to the radiator filler port. At this time, mix the antifreeze or antirust agent. When adding coolant, do so slowly to avoid mixing air bubbles in the system.
2
9. Run the engine at slow idle for several minutes. Check if no coolant leaks at drain cocks (2), (3). Run the engine with gradually increase its speed for about ten more minutes, increase coolant temperature until the needle of the temperature gauge reaches the green zone (5) to sufficiently bleed the air from the cooling system. IMPORTANT: After adding coolant, remaining air circulates inside the engine. Avoid sudden acceleration or sudden no load operation right after starting the engine. 10. After adding coolant, operate the engine for several minutes. Check the coolant level of the reserve tank again. Add coolant if necessary.
M1J7-07-022
3
M1J1-07-044
7-87
MAINTENANCE Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Core Outside --- every 500 hours Inside --- once a year WARNING: Use reduced compressed air pressure d(Less than 0.2 MPa, 2 kgf/cm ) for cleaning purposes. 2
Radiator
Oil Cooler
Wear personal protection equipment including eye protection.
IMPORTANT: If air with pressure of higher than 0.2 MPa (2 kgf/cm2) or tap water with high delivery pressure is used for cleaning, damage to the radiator/oil cooler/ inter cooler fins may result. If dirt or dust is accumulated on the cores of radiator, oil cooler or inter cooler (ZX870-5 class), cooling system performance decreases. Clean them with compressed air pressure (lower than 0.2 MPa (2 kgf/cm2)) or tap water. It will prevent a reduction in cooling system performance.
Air Conditioner Condenser
Inter Cooler
M16J-07-064
ZX470-5 class
Oil Cooler
Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Front Screen --- every 500 hours IMPORTANT: Check the screen daily and replace it if necessary when the machine is operated in dusty areas.
Radiator
Air Conditioner Condenser
ZX870-5 class
Clean Air Conditioner Condenser --- every 500 hours IMPORTANT: Check the screen daily and replace it if necessary when the machine is operated in dusty areas.
7-88
MJAC-07-055
MAINTENANCE H. Air Conditioner
1
Clean and Replace Air Conditioner Filter Clean Circulating/Fresh Air Filters Circulating Air Filter ... Every 250 hours Fresh Air Filter
2
... Every 250 hours
Replace Circulating/Fresh Air Filters Circulating Air Filter ... When the filters are severely clogged or after cleaning 6 times Fresh Air Filter
MDAA-07-040
... 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).
4
2. While pressing knobs (4) on both sides of fresh air filter (3) inward, horizontally remove the fresh air filter.
3
M1U1-07-011
5
Removing Recirculation Filter 1. Recirculation filter (5) is located under the rear tray. 2. Holding grips (6), pull them toward you to remove.
6
MDAA-07-039
7-89
MAINTENANCE WARNING: When using compressed air pressure d(less than 0.2 MPa (2 kgf/cm )), wear safety glasses or 2
goggles.
Cleaning Clean the circulating and fresh air filters. Clean both the external and internal filters by blowing compressed air or washing with water. Washing procedure with water is as follows: 1. Use tap water. 2. Submerge the filter in water containing a neutral detergent for about 5 minutes. 3. Clean the filter with water again. 4. Dry the filters.
Installation When installing the cleaned circulating/fresh air filter or new filters, follow the reverse order of the Removing Filter procedures described on the previous page.
Rear Side of Cab
Fresh Air 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. Circulating Air Filter While contacting the attached filter plate onto the duct, install the filter so that the clips align with the duct mounting holes.
Operator's Seat Side M1U1-07-013 Support
MDAA-07-039
7-90
MAINTENANCE Check Air Conditioner --- every 250 hours Check pipe connections for refrigerant gas leakage If oil seepage is found around pipe connections, it indicates possible gas leakage. Check Refrigerant Start the engine and run at 1500 min-1(rpm). Turn the air conditioner switch ON. Set the blower switch to HI and set the temperature control switch to the coolest position (18 °C on the monitor screen). Operate the air conditioner 2 to 3 minutes. Check if cool air comes out from the vent in the cab. Kind of refrigerant and amount when shipping the machine Model ZX470-5 class ZX870-5 class
Type
Amount
HFC134a
1.05±0.05 kg
Check the condenser If the condenser fins become clogged with dirt or insects, the cooling effect will be decreased. Be sure to keep it clean at all times. (Refer to "Clean Air Condenser" in Maintenance Section.) Check compressor After operating the air conditioner for 5 to 10 minutes, touch the high-pressure side and low-pressure side pipes with your hand. If normal, the high-pressure side pipe will be hot, and the low-pressure side cold.
7-91
MAINTENANCE Adjust Compressor Belt Tension --- every 250 hours
Fan Pulley
Check fan belt tension by depressing the midpoint between the crank pulley and the idle pulley with the thumb. Deflection must be as follows with a depressing force of approximately 98 N (10 kgf ). Deflection: approx. 6 to 10 mm If tension is not within specifications, loosen the bolts for the idle pulley mounting bracket to adjust belt tension. Visually check the belt for wear. Replace if necessary.
Alternator Pulley
Idle Pulley Push (about 98N, 10kgf)
Deflection 6 to 10 mm
Crank Pulley
Air Compressor Pulley
ZX470-5 class Push (about 98N, 10kgf)
M16J-07-053 Idle Pulley Deflection 6 to 10 mm
Crank Pulley Air Compressor Pulley
ZX870-5 class
M1J1-07-064
ZX470-5 class
MJAC-07-001
ZX870-5 class
MJAC-07-002
Check Looseness at Each of Fastened Areas --- every 250 hours Check tightness of compressor or other mounting bolts, hose connections and fittings. Check tightness after the first 50 hours then check every monthly inspection. Torque Specifications for Hose Connections: Tightening Torque: Wrench size mm N·m (kgf·m) 19 15 to 20 (1.5 to 2.0) 24 25 to 30 (2.5 to 3.0) 27 30 to 35 (3.0 to 3.5)
7-92
MAINTENANCE Check at Preseason and Off-Season --- Twice a year Preseason maintenance IMPORTANT: Before beginning of 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 circulating and fresh air filters, line connections, pressure switches and inspection and cleaning of evaporator. Off-season maintenance Do not attempt to loosen connections dinWARNING: air conditioning circuit when the air conditioner
malfunctions. Doing so may cause high pressure gas to spout, resulting in serious injury. Keep hands back.
IMPORTANT: Do not remove the air compressor driving belt during off-season. Consult your authorized dealer for repairing the air conditioner. 1. Operate the compressor once a week at low speed for several minutes in order to maintain its parts in well lubricated condition. 2. Be sure to run the engine at slow idle and place the temperature control switch in MEDIUM COOL. This operation also prevents refrigerant leakage caused by dried up shaft seal. 3. Check for refrigerant leakage. If the refrigerant level is low during off-season, rust will be formed inside the circuit.
7-93
MAINTENANCE I. Electrical System IMPORTANT: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment affect the machine's electronic parts, causing involuntary movement of the machine. Incorrectly installed electrical equipments may cause unexpected machine failure and/or a fire on the machine. Be sure to consult your nearest Hitachi dealer when required to install radio communication equipment or additional 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.
SA-032
Battery
d WARNING: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check electrolyte level. Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. Charge the batteries in a well ventilated location. 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. To avoid hazards: 1. Charge batteries in a well ventilated place. 2. Wearing eye protection and rubber gloves. 3. When refilling electrolyte, do not inhale gas. 4. Do not spill or drop electrolyte. 5. Perform jump-starting in the correct procedure.
7-94
SA-036
MAINTENANCE If electrolyte spills on your skin and/or clothes: 1. Immediately flash the skin with water. 2. Sprinkle sodium hydrogen carbonate or caustic lime to neutralize an acid. 3. If electrolyte is accidentally splashed into eyes, flush with water for 15 to 30 minutes and get emergency medical attention.
Batteries Location
In case electrolyte is swallowed: 1. Do not attempt to make the exposed person vomit. 2. Give the person large amounts of water or milk. 3. Get emergency medical attention. IMPORTANT: When the battery is required to refill distilled water in cold weather, refill water before starting work in the day or before charging the battery. If the battery is used with the electrolyte level lower than the specified lower level, the battery may deteriorate quickly. Do not supply battery electrolyte more than the specified upper level. Electrolyte may spill, damaging the painted surfaces and/or corroding other machine parts.
ZX470-5 class
M1J1-07-014
ZX870-5 class
MJAA-07-054
f 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. Or, consult the battery maker.
7-95
MAINTENANCE Electrolyte Level Check --- every one month Check the electrolyte level at least once a month. 1. Park the machine on level ground and stop the engine. 2. Check Electrolyte Level 2.1 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 with 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.
2.2 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 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.
U.L (Upper Level) L.L (Lower Level) M146-07-109 Filler Port
Sleeve
U.L (Upper Level) L.L (Lower Level)
Separator Top M146-07-110
Proper 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
Lower When the electrolyte surface is lower than the bottom end of the sleeve, the electrode ends are seen straight. M146-07-112
After refilling, securely tighten the filler plug.
Be sure to refill with distilled water before recharging (operating the machine).
2.3 When an indicator is available to check the level, follow the checking results. 3. Always keep around the battery terminals clean to prevent battery discharge. Check terminals for loose and/or rust.
Check terminals for loose and/or rust. Coat terminals with grease or petroleum jelly to prevent corrosion build up. M409-07-072
7-96
MAINTENANCE Check electrolyte specific gravity --- every one month
d WARNING:
If electrolyte spills on your skin and/or clothes: 1. Immediately flash the skin with water. 2. Sprinkle sodium hydrogen carbonate or caustic lime to neutralize an acid. 3. If electrolyte is accidentally splashed into eyes, flush with water for 15 to 30 minutes and get emergency medical attention.
Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check electrolyte level. Battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into the eyes.
In case electrolyte is swallowed: 1. Do not attempt to make the exposed person vomit. 2. Give the person large amounts of water or milk. 3. Get emergency medical attention.
Never attempt to contact a metal bar to the electrode to check charge condition. Use a voltmeter or hydrometer.
IMPORTANT: Measure the electrolyte specific gravity when the electrolyte temperature is equal to the atmospheric temperature. Do not check the electrolyte specific gravity immediately after operation as the correct value can not be obtained.
To avoid hazards: 1. Charge batteries in a well ventilated place. 2. Wearing eye protection and rubber gloves. 3. When refilling electrolyte, do not inhale gas. 4. Do not spill or drop electrolyte. 5. Perform jump-starting in the correct procedure.
Check the electrolyte specific gravity for each battery cell. The electrolyte specific gravity varies depending on change in the 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 40 °C 20 °C Fluid temp.
Working Range
0 °C –20 °C –40 °C
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
Specific gravity of battery fluid
7-97
1.29
1.30
1.31
1.32
1.33 M104-07-054
MAINTENANCE Replacement of Battery IMPORTANT: Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine. If the machine is equipped with the battery disconnect switch (optional), turn the disconnect switch OFF. This machine provides two 12 V batteries. The negative (-) terminal is grounded. In the 24 V system, in case one of two batteries (12 V) is deteriorated but another one is still available, change the deteriorated one with a new same type of battery. If a maintenance free battery is deteriorated, change it with same type of new maintenance free battery, for example. Different type of battery has different charging capacity. If different type batteries are charged at the same time, battery may be overloaded, malfunction of batteries may result.
7-98
MAINTENANCE Replacing Fuses --- as necessary
Fuse Box 1
Fuse Box 2
If any electrical equipment fails to operate, first check the fuses. Fuse box is located behind the operator's seat.
f NOTE: One each spare fuse for respective fuse capacities is provided in the fuse box. A fuse removing jig is provided in the fuse box. Fuse Box 1 10- CONTROLLER
5A
20- OPTION3
5A
9- BACKUP
10 A
19- HORN
10 A
8- ECF
5A
18-
7- START
5A
17- POWER ON
5A
10
20
6- OPTION2
20 A
16- GLOW. R
5A
9
19 18
MDAA-01-297 Spare Fuses
5- OPTION1
5A
15- AUXLIALY
10 A
8
4- SOLENOID
10 A
14- MONITOR
5A
7
17
3- HEATER
20 A
13- LIGHTER
10 A
6
16
2- WIPER
10 A
12- RADIO
5A
5
15
1- LAMP
20 A
11- EC MOTOR
10 A
4
14
3
13
2
12
1
11
Fuse Box 2 30- AUTO LUB.
10 A
40- SPARE
29- LIGHT1
20 A
39- SPARE
28- PCV
15 A
38- SPARE
27- AUXLIALY3
5A
37- SPARE
26- QUICK HITCH
5A
36- SPARE
25- IMOBI
5A
35- LUBRICATOR
10 A
30
40
24- 12V UNIT
10 A
34- AUXILIARY2
10 A
29
39
23- CAB LAMP REAR 10 A
33- WARNING LAMP 10 A
28
38
22- CAB LAMP FRONT
10 A
32- CAB LAMP FRONT+2
10 A
27
37
26
36
21- SEAT HEATER
10 A
31- SEAT COMPR.
10 A
25
35
24
34
23
33
22
32
21
31
M1GR-01-003
M1GR-01-003
7-99
MAINTENANCE Fusible Link (Main Fuse) In case the starter won't rotate even if the key switch is turned to the START position, fusible link may be the cause of the trouble. Remove the cover next to the engine coolant reservoir to check the fuse. Replace it if blown.
21
21- + Side (Red) 45 A 22- – Side (Black) 65 A
22
Battery
MJAA-07-055
ZX470-5 class
21 22
Battery
ZX870-5 class
7-100
MJAA-07-056
MAINTENANCE J. Miscellaneous Check and Replace Bucket Teeth ---daily Check bucket teeth (1) for wear and looseness. Replace teeth (1) if tooth wear exceeds the designated service limit shown below. Model
Kind of Bucket
New
ZX470-5 class ZX870-5 class
Standard Bucket Rock Bucket Standard Bucket Rock Bucket
254 mm 280 mm 306 mm 315 mm
Limit of Use 120 mm 140 mm 160 mm 160 mm
1
2
Parts No. 4471407 4350781 4472424 4255718
A
M1J1-07-065
IMPORTANT: 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. Procedures:
d WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, and safety equipment appropriate to the job. Removing the tooth point 1. 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).
1
2
M1J1-07-066
7-101
MAINTENANCE 2. Driving out locking pin
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).
2 1
3
M1J1-07-067
3. Removing the tooth point
Turn tooth point (1) to the left, twist and pull it toward you to remove it.
IMPORTANT: Check if lock pin (3) has cracks. If it has, replace the lock pin (3) 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).
3
M1J1-07-068
1
Mounting the tooth point 1. Mounting the tooth point
Clean the top end of the adapter nose. Also check that lock pin (3) has no cracks.
If pebbles, dirt, etc., are stuck to the adapter nose, tooth point (1) will not insert properly and the pin cannot be driven in.
Insert tooth point (1) slowly until the tooth point comes to the end of the adapter nose while twisting and turning it to the right.
M1J1-07-066
1
2
M1J1-07-066
7-102
MAINTENANCE Inserting the lock pin Insert lock pin (3) facing toward adapter (2) nose. With tooth point (1) fully inserted onto adapter (2), tap lock pin (3) into tooth point (1) with a hammer until the top of lock pin (3) comes flat with the nose surface. (i.e. until lock pin (3) fits into the grooves of tooth point (1).) Tap lock pin (3) into tooth point (1) with a hammer until the top of lock pin (3) comes flat with the nose surface.
3
1
2
Other Precautions 1. Lock pin (3) is a pin integrated with rubber. Since rubber is susceptible to corrosion, do not use grease, oil and other oily materials when inserting lock pin (3). Do not use grease, oil and other oily materials when inserting lock pin (3). 2. In mounting welding-type nose and adapter (2) onto the bucket, lock pin (3) should be removed from the nose when preheating and welding. Otherwise the rubber will be spoiled.
M1J1-07-070
Tap lock pin (3) into tooth point (1) with a hammer until the top of lock pin (3) comes flat with the nose surface.
3 Nose Surface
1 M1J1-07-071 Upper Side
3
Tooth Side
Adapter Side
Lower Side
7-103
M1J1-07-077
MAINTENANCE Change Bucket ---As required CAUTION: When driving the connecting pins in or dout, guard against injury from flying pieces of metal
or debris. Wear goggles or safety glasses, hard hat and face shield.
Before starting converting work, keep bystanders clear of the machine. Slowly move the front attachment. When using a signal person, coordinate hand signals before starting. Removal
2
Separation Type O-ring Removal Method
1
1. Place the bucket in a stable position. 2. Loosen nut (2). Remove separation type O-ring (1). 3. Remove bucket pins A and B to separate the arm and bucket.
Separation Section
2 2 1 M1J1-07-074
Separation Type O-Ring
Link Arm
B A
Bucket M503-07-056
7-104
MAINTENANCE Installation Separation Type O-ring Installation Method
Link
1. Clean the pins and pin bores. Apply sufficient grease to the pins and pin bores.
B
2. Place the new bucket in stable position as shown in the figure.
A
3. Fit the arm and alternate bucket. Be sure the bucket will not roll. Install bucket pins A and B. 4. Install the locking pins and snap rings on pins A and B. 5. Install separation type O-ring (1) in the direction as illustrated to the right so that the separation section of O-ring (1) does not directly come in contact with soil to protect separation type O-ring (1) from being damaged quickly by soil or foreign matter.
M503-07-056
2 1
6. Install O-ring (1) with care not to make a gap in the separation section of O-ring (1). 7. Cut off the bolt so that the extended part from nut (2) becomes 10 mm to 20 mm to protect the separation type O-ring (1) from damaging when soil comes in contact with the bolt.
2
Separation Section
8. Apply grease to each pin. 9. Start the engine and run at slow idle. Slowly operate the bucket in both directions to check for any interference in bucket movement.
7-105
Cut off the bolt extended from the nut. (Length of the Extended Part: 10 mm to 20 mm)
1 2
M1J1-07-074
MAINTENANCE Removal
O-Ring Shift
3
Solid Type O-ring Removal Method 1. Place the bucket in a stable position. 2. Slide solid type O-rings (3) out of the way, as shown. 3. Remove bucket pins A and B to separate the arm and bucket.
Bucket Boss Link Arm
B A
Bucket M104-07-063
Installation Solid Type O-ring Installation Method Link
1. Clean the pins and pin bores. Apply sufficient grease to the pins and pin bores.
B
2. Place the new bucket in stable position as shown in the figure.
A
3. Install solid type O-ring (3) onto the bucket boss A and B. 4. Join the arm with the hole A, and the link with the hole B with pins. 5. Install the locking pins and snap rings on each pin.
M503-07-056
6. Install O-ring (3) (seal ring) to the specified positions. 7. Apply grease to each pin.
O-Ring Shift
8. Start the engine and run at slow idle. Slowly operate the bucket in both directions to check for any interference in bucket movement.
3
Bucket Boss M116-07-090
7-106
MAINTENANCE Adjust Bucket Linkage With a bucket attached to the arm, push the bucket on one side and adjust the shims so that the clearance between the bucket and the arm end becomes 0.5 mm to 1.5 mm. (Two 1 mm shims and two 2 mm shims are shipped together with the machine) Model ZX470-5 class ZX870-5 class
Parts No.
Shim Thickness
4264609
1 mm
4264610
1.6 mm
4643721
1 mm
4643720
2 mm
Shim Adjustment Position
M104-07-063
Bucket
Adjust the shims so that the clearance is 0.5 to 1.5 mm.
Pin
M1JB-07-057 Shims Arm
7-107
MAINTENANCE Remove Travel Levers The travel levers may be removed if desired. Procedure:
3
4
Remove bolts (1) and (2) to remove travel levers (3) and (4) from brackets.
f NOTE: Wrench size: 17 mm Tightening Torque: 50 N·m (5.0 kgf·m)
2
1
M178-07-077
Check and Replace Seat Belt Check --- daily Replace --- every 3 years 5
Prior to operating the machine, thoroughly examine belt (5), buckle (6) and attaching hardware (7). 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
7
M1U1-07-008
6
5
7
M1U1-07-009
7-108
MAINTENANCE Check Windshield Fluid Level 1
Check fluid in windshield washer tank (1). If the fluid level is low, remove the cap and add fluid via the opening.
ZX470-5 class
MJAA-07-082
1
ZX870-5 class
7-109
MJAA-07-084
MAINTENANCE Check Track Sag --- every 50 hours Swing the upperstructure 90° and lower the bucket to raise the track off the ground as shown. 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. Each time, be sure to place blocks under the machine frame to support the machine.
M104-07-067
To prevent accidents, care should be taken dtoCAUTION: ensure that hands, feet, and any body parts do not become entangled when working around the tracks.
Model ZX470-5G ZX470H-5G ZX470R-5G ZX470LC-5G ZX470LCH-5G ZX470LCR-5G ZX870-5G ZX870H-5G ZX870LC-5G ZX870LCH-5G ZX870LCR-5G
Appropriate sag A (mm) 380 to 430 390 to 440 M107-07-068
450 to 500 470 to 530
f NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.
Adjust 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 both side track sags, rotate the tracks backward and forward to equalize both side track sags. 4. Recheck the track sag once more. Readjust as necessary.
7-110
MAINTENANCE Loosen the Track CAUTION: The pressure inside the cylinder of the dtrack adjuster is high. Do not loosen valve (1) quickly
or loosen it too much as valve (1) may fly out or highpressure grease in the adjusting cylinder may spout out. Slowly loosen valve (1) while 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. M107-07-075
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.
2
1
Do not loosen the valve over that turns.
3. If grease does not drain smoothly, slowly rotate the raised track. To prevent accidents, care should be taken dtoCAUTION: ensure that hands, feet, and any body parts do not
Grease Outlet
become entangled when working around the tracks. 4. When proper track sag is obtained, turn valve (1) clockwise to the original condition.
M16J-07-083
Tightening Torque: 150 N·m (15 kgf·m)
CAUTION: Consult your authorized dealer if grease is dnot sufficiently drained.
2
M16J-07-083
7-111
MAINTENANCE Tighten the Track CAUTION: It is abnormal if the track can not be dadjusted. The strong force acts on the spring in track
2
adjuster. Therefore, the grease in cylinder is highly pressurized. 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. M16J-07-083
Replace the Track 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.
7-112
MAINTENANCE Clean Cab Floor --- as required IMPORTANT: When cleaning the cab floor with tap water, spray the floor only. Take care not to splash the surrounding area. Do not increase water spray speed by restricting the hose end, and do not use high pressure steam for cleaning. 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, sweep dust or water through a cleaning hole.
7-113
MDAA-07-041
MAINTENANCE Retighten Cylinder Head Bolt --- as required See your authorized dealer. Inspect and Adjust Valve Clearance --- every 1000 hours See your authorized dealer. Check of Fuel Injection Timing --- as required See your authorized dealer. Measure Engine Compression Pressure --- every 1000 hours See your authorized dealer. Check Starter and Alternator --- every 1000 hours See your authorized dealer. Check Water Pump --- every 4000 hours See your authorized dealer. Check and Replace Injection Nozzle --- every 500 hours See your authorized dealer.
7-114
MAINTENANCE Check Gas Damper --- as required CAUTION: The gas damper has been charged with dhigh-pressure nitrogen gas. Inappropriate handling may cause explosion, possibly resulting in serious injury or death.
The gas dampers are used in the engine cover and the cab overhead window. Contact your nearest HITACHI dealer immediately at any of the following situations. The cover or window can not be opened with normal operating force. The cover or window can not maintain its open position. Oil or gas leak is found.
Check Cushion Rubber of Handrail (ZX470-5 class) --- Every 2 years or 4000 hours whichever comes first
1
Cushion rubber (1) is attached to the handrails. If cracks or damage is found on the cushion rubber, it may result in early damage of the handrail. Check the condition of the cushion rubber, if there are cracks and/or damages, replace it.
Tightening and Retightening Torque of Nuts and Bolts --- every 250 hours (first time after 50 hours) Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Bolts and nuts should be replaced with those of the same or higher grade. Check tightness after the first 50 hours then every 250 hours. For tightening nuts and bolts other than specified in the table below, refer to the Tightening Torque Chart at the end of this section.
7-115
1
MJAC-07-003
MAINTENANCE ZX470-5 class No.
Bolt dia. mm
Quantity
Wrench size
22 22 18 14 16 16 16 1-3/16-12UNF 1-7/16-12UNF 12 20 20 22
2 2 4 8 4 8 8
12 4 6 26
18
24
12 16 22 30 27 22 18 22 18 22 22 24 24 22 22 22 8 1/4-28 UNF 45 24
2 6 2 36 36 40 8 48 16 64 72 392 424 16 44 50
10
4
20 20
15 7
25. Pilot pump mounting bolt
10
2
26. Air compressor mounting bolt
8
4
32 32 27 22 24 24 24 36 41 19 30 30 32 14 (socket hole) 19 24 32 46 41 32 27 32 27 32 32 32 32 32 32 32 13 11 65 36 8 (socket hole) 30 30 8 (socket hole) 13
1.
Descriptions Engine cushion rubber mounting bolt
Fan side
2. 3. 4. 5.
Engine - Cushion rubber Pump side Cushion Rubber - Main Body Engine bracket mounting bolt Radiator mounting bolt Hydraulic oil tank mounting bolt Fuel tank mounting bolt
6.
ORS fittings for hydraulic hoses and piping
7. 8. 9. 10.
Pump transmission mounting bolt Control valve mounting bolt Control valve bracket mounting bolt Swing device mounting bolts
11. Swing motor mounting bolt 12. Battery mounting bolt 13. Cab mounting nut 14. Cab anchor mounting bolt Swing bearing Upperstructure side 15. Undercarriage side mounting bolts Travel device mounting bolt 16. Travel motor mounting bolt Sprocket mounting bolt 17. Upper roller mounting bolt Lower roller mounting STD, H, R 18. LC, LCH, LCR bolt Track shoe mounting STD, H, R 19. LC, LCH, LCR bolt STD track guard Track guard mounting 20. STD full-track guard bolt LC full-track guard Flexible master coupling 21. Low pressure piping T-bolt clamp 22. Counterweight mounting bolt 23. Signal control valve mounting bolt 24.
Front pin-retaining bolt Front pin-retaining nut
*
Remark
2 4
LOCTITE
* * * *
* * *
Torque N·m (kgf·m) 750 (76.5) 750 (76.5) 400 (41.0) 180 (18.5) 210 (21.5) 270 (27) 210 (21) 180 (18) 210 (21) 90 (9) 400 (40) 400 (40) 750 (75) 300 (30)
35 (3.5) 210 (21) 550 (55) 1950 (195) 1400 (140) 750 (75) 300 (30) 750 (75) 400 (40) 750 (75) 750 (75) 1370 (137) 1370 (137) 750 (75) 750 (75) 750 (75) 11 to 13 (1.1 to 1.3) 10 (1.0) 2400 (240) 450 (45) 50 (5) 400 (40) 400 (40) 50 (5) 25 to 30 (2.5 to 2.9)
: If a loose bolt is found, remove the bolt. Remove the LOCTITE coating remaining in the bolt hole and clean inside the bolt hole. After applying LOCTITE to the bolt, reinstall the bolt. In case the bolt has been deformed, replace the bolt with a new one. : Bolt tightening force is expressed in torque. For example, when you apply 120N (12 kg) force at the edge of 1 m long wrench, the torque is 120 N·m (12 kgff·m) (1 m ×1 120N). In order to get same torque by using 25 cm wrench, you need to apply 480 N force because 0.25 m times required force equals 120 N·m, so 120N/0.25m=480 N.
7-116
MAINTENANCE 1. Engine cushion rubber mounting bolt
Mounting bolt (fan side) Wrench size
: 32 mm
Tightening torque : 750 N·m (76.5 kgf·m)
Mounting bolt (pump side)
(Engine – Cushion rubber) Wrench size
: 32 mm
Tightening torque : 750 N·m (76.5 kgf·m) MJAC-07-004
Cushion Rubber - Main Body Wrench size
: 27 mm
Tightening torque : 400 N·m (41.0 kgf·m)
2. Engine bracket mounting bolt
Mounting Bolt Wrench size
: 22 mm
Tightening torque : 180 N·m (18.5 kgf·m)
MJAC-07-005
7-117
MAINTENANCE 3. Radiator mounting bolt Wrench size
: 30 mm
Tightening torque : 550 N·m (55 kgf·m)
MJAA-07-087
4. Hydraulic oil tank Wrench size
: 24 mm
Tightening torque : 270 N·m (27 kgf·m)
MJAA-07-109
5. Fuel tank mounting bolt Wrench size
: 24 mm
Tightening torque : 210 N·m (21 kgf·m)
M111-07-069
6. ORS fittings for hydraulic hoses and piping Wrench size
: 36 mm
Tightening torque : 180 N·m (18 kgf·m) Wrench size
: 41 mm
Tightening torque : 210 N·m (21 kgf·m)
M110-07-048
7-118
MAINTENANCE 7. Pump transmission mounting bolt Wrench size
: 19 mm
Tightening torque : 90 N·m (9 kgf·m)
MJAC-07-006
8. Control valve mounting bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1J1-07-020
9. Control valve bracket mounting bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1J1-07-052
10. Swing device mounting bolts Wrench size
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
M1J1-07-001
7-119
MAINTENANCE 11. Swing motor mounting bolt Wrench size
: 14 mm Hexagonal socket wrench
Tightening torque : 300 N·m (30 kgf·m)
M1J1-07-001
12. Battery mounting bolt Wrench size
: 19 mm
Tightening torque : 35 N·m (3.5 kgf·m)
M1J1-07-014
13. Cab mounting nut Wrench size
: 24 mm
Tightening torque : 210 N·m (21 kgf·m)
M1U1-07-026
14. Cab anchor mounting bolt Wrench size
: 32 mm
Tightening torque : 550 N·m (55 kgf·m)
M1U1-07-054
7-120
MAINTENANCE 15. Swing bearing mounting bolts
Upperstructure side Wrench size
: 46 mm
Tightening torque : 1950 N·m (195 kgf·m)
M166-07-013
Undercarriage side
Remove cover. Tighten the inside bolt. Wrench size
: 41 mm
Tightening torque : 1400 N·m (140 kgf·m)
M1J1-07-024
16. Travel device mounting bolt Wrench size
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
Travel motor mounting bolt Wrench size
: 27 mm
Tightening torque : 300 N·m (30 kgf·m)
Sprocket mounting bolt Wrench size
M1J1-07-048
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
M111-07-078
7-121
MAINTENANCE 17. Upper roller mounting bolt Wrench size
: 27 mm
Tightening torque : 400 N·m (40 kgf·m)
M1J1-07-026
18. Lower roller mounting bolt Wrench size
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
M107-07-092
19. Track shoe mounting bolt Wrench size
: 32 mm
Tightening torque : 1370 N·m (137 kgf·m)
M107-07-093
20. Track guard mounting bolt Wrench size
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
M1J1-07-025
7-122
MAINTENANCE 21. Flexible master coupling and T-bolt clamp of low pressure piping
Flexible master coupling of low pressure piping Wrench size
: 13 mm
Tightening torque : 10.5 to 12.5N·m (1.05 to 1.25 kgf·m)
M1G6-07-008
T-bolt clamp Wrench size
: 11 mm
Tightening torque : 10 N·m (1.0 kgf·m)
M1J1-07-037
7-123
MAINTENANCE 22. Counterweight mounting bolt Wrench size
: 65 mm
Tightening torque : 2400 N·m (240 kgf·m)
M1J1-07-036
Wrench size
: 36 mm
Tightening torque : 450 N·m (45 kgf·m)
M162-07-070
23. Signal control valve mounting bolt Wrench size
: 8 mm Hexagonal socket wrench
Tightening torque : 50 N·m (5 kgf·m)
M1J1-07-030
7-124
MAINTENANCE 24. Front pin retaining bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1J1-07-017
M111-07-083
M111-07-084
7-125
MAINTENANCE Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M111-07-085
Front pin retaining nut Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M111-07-086
25. Pilot pump mounting bolt Wrench size
: 8 mm Hexagonal socket wrench
Tightening torque : 50 N·m (5 kgf·m)
MJAC-07-007
26. Air compressor mounting bolt Wrench size
: 13 mm
Tightening torque : 25 to 30 N·m (2.5 to 2.9 kgf·m)
M1J1-07-083
7-126
MAINTENANCE ZX870-5 class No.
Descriptions Fan side Pump side Fan side Pump side
1.
Engine cushion rubber mounting bolt
2.
Engine bracket mounting bolt
3. 4. 5. 6.
Radiator mounting bolt Oil cooler mounting bolt Hydraulic oil tank mounting bolt Fuel tank mounting bolt
7.
ORS fittings for hydraulic hoses and piping
8. 9. 10. 11. 12. 13.
15. 16. 17.
Pump transmission mounting bolt Pump transmission mounting bolt Fan pump mounting bolt Fan motor mounting nut Control valve mounting bolt Control valve bracket mounting bolt Swing device mounting bolts Ring gear housing mounting bolt Swing motor mounting bolt Battery mounting bolt Cab mounting nut
18.
Swing bearing mounting bolts
14.
19. 20.
Travel device mounting bolt Travel motor mounting bolt Sprocket mounting bolt Upper roller mounting bolt
21.
Lower roller mounting bolt
22.
Track shoe mounting bolt
23.
Track guard mounting bolt
24.
Track mounting bolt
25.
Low pressure piping
26. 27. 28. 29. 30. 31. 32.
Upperstructure side Undercarriage side
STD, H, R LC, LCH, LCR STD, H, R LC, LCH, LCR STD track guard STD full-track guard LC full-track guard Flexible master coupling T-bolt clamp
Counterweight mounting bolt Counterweight retaining bolt Signal control valve mounting bolt Front pin retaining bolt Front pin retaining nut Fan mounting bolt Fan drive coupling mounting nut Pilot pump mounting bolt Side branch piping bracket mounting bolt Air compressor mounting bolt
*
Remark
Bolt dia. mm
Quantity
Wrench size
27 33 14 20 27 24 20 18 1-3/16-12UNF 1-7/16-12UNF 12 20 16 12 20 20 24 20 12 12 16 33 30 27 18 27 22 24 24 27 27 27 27 27 36 8 1/4-28 UNF 45 24 10 20 20 12 16 10 14 8
2 2 8 12 4 4 8 8
41 50 22 30 41 36 30 27 36 41 19 17 (socket hole) 14 (socket hole) 19 30 30 36 17 (socket hole) 12 (socket hole) 19 24 50 46 41 27 41 32 36 36 41 41 41 41 41 55 13 11 65 36 8 (socket hole) 30 30 10 (socket hole) 24 8 (socket hole) 22 13
14 4×2 4 2 4 8 14×2 12×2 12×2 2 6 41 48 24×2 4×2 24×2 24 64 72 376 408 16 32 36 44
2 4 4 24 7 6 1 2 4 4
LOCTITE
* *
* *
*
* *
* *
Torque N·m (kgf·m) 1050 (105) 1950 (195) 210 (21) 400 (40) 1050 (105) 950 (95) 400 (40) 300 (30) 180 (18) 210 (21) 110 (11) 400 (40) 210 (21) 110 (11) 400 (40) 400 (40) 950 (95) 440 (44) 90 (9.0) 35 (3.5) 210 (21) 2200 (220) 1750 (175) 1400 (140) 300 (30) 1400 (140) 750 (75) 950 (95) 950 (95) 2000 (200) 2000 (200) 1400 (140) 1400 (140) 1400 (140) 2800 (280) 11 to 13 (1.1 to 1.3) 10 (1.0) 2800 (280) 700 (70) 50 (5.0) 400 (40) 400 (40) 90 (9.0) 100 (10) 50 (5.0) 140 (14) 25 to 30 (2.5 to 3.0)
: If a loose bolt is found, remove the bolt. Remove the LOCTITE coating remaining in the bolt hole and clean inside the bolt hole. After applying LOCTITE to the bolt, reinstall the bolt. In case the bolt has been deformed, replace the bolt with a new one. : Bolt tightening force is expressed in torque. For example, when you apply 120N (12 kg) force at the edge of 1 m long wrench, the torque is 120 N·m (12 kgff·m) (1 m ×1 120N). In order to get same torque by using 25 cm wrench, you need to apply 480 N force because 0.25 m times required force equals 120 N·m, so 120N/0.25m=480 N.
7-127
MAINTENANCE 1. Engine cushion rubber mounting bolt
Mounting bolt (fan side) Wrench size
: 41 mm
Tightening torque : 1050 N·m (105 kgf·m)
Mounting bolt (pump side)
(Engine – Cushion rubber) Wrench size
: 50 mm
Tightening torque : 1950 N·m (195 kgf·m) 2. Engine bracket mounting bolt
MJAC-07-008
Mounting bolt (fan side) Wrench size
: 22 mm
Tightening torque : 210 N·m (21 kgf·m)
Mounting bolt (fan side) Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
7-128
MAINTENANCE 3. Radiator mounting bolt Wrench size
: 41 mm
Tightening torque : 1050 N·m (105 kgf·m)
M1JB-07-011
4. Oil cooler mounting bolt Wrench size
: 36 mm
Tightening torque : 950 N·m (95 kgf·m)
M1JB-07-021
5. Hydraulic oil tank mounting bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1JB-07-025
6. Fuel tank mounting bolt Wrench size
: 27 mm
Tightening torque : 300 N·m (30 kgf·m)
M1JB-07-021
7-129
MAINTENANCE 7. ORS fittings for hydraulic hoses and piping Wrench size
: 36 mm
Tightening torque : 180 N·m (18 kgf·m)
M1JB-07-004
Wrench size
: 41 mm
Tightening torque : 210 N·m (21 kgf·m)
M162-07-067
8. Pump transmission mounting bolt Wrench size
: 19 mm
Tightening torque : 110 N·m (11 kgf·m)
MJAC-07-047
9. Main pump mounting bolt Wrench size
: 17 mm Hexagonal socket wrench
Tightening torque : 400 N·m (40 kgf·m)
MJAC-07-047
7-130
MAINTENANCE 10. Fan pump mounting bolt Wrench size
: 14 mm Hexagonal socket wrench
Tightening torque : 210 N·m (21 kgf·m)
MJAC-07-009
11. Fan motor mounting nut Wrench size
: 19 mm
Tightening torque : 110 N·m (11 kgf·m)
MJAC-07-010
12. Control valve mounting bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1J7-07-016
13. Control valve bracket mounting bolt Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1JB-07-045
7-131
MAINTENANCE 14. Swing device mounting bolts Wrench size
: 36 mm
Tightening torque : 950 N·m (95 kgf·m)
Ring gear housing mounting bolt Wrench size
: 17 mm Hexagonal socket wrench
Tightening torque : 440 N·m (44 kgf·m)
MJAA-07-099
15. Swing motor mounting bolt Wrench size
: 12 mm Hexagonal socket wrench
Tightening torque : 90 N·m (9.0 kgf·m)
MJAA-07-099
16. Battery mounting bolt Wrench size
: 19 mm
Tightening torque : 35 N·m (3.5 kgf·m)
M1JB-07-012
17. Cab mounting nut Wrench size
: 24 mm
Tightening torque : 210 N·m (21 kgf·m)
M1U1-07-026
7-132
MAINTENANCE 18. Swing bearing mounting bolts
Upperstructure side Wrench size
: 50 mm
Tightening torque : 2200 N·m (220 kgf·m)
M17V-07-009
Undercarriage side
Remove cover. Tighten the inside bolt. Wrench size
: 46 mm
Tightening torque : 1750 N·m (175 kgf·m)
M1J1-07-024
19. Travel device mounting bolt Wrench size
: 41 mm
Tightening torque : 1400 N·m (140 kgf·m)
Travel motor mounting bolt Wrench size
: 27 mm
Tightening torque : 300 N·m (30 kgf·m))
Sprocket mounting bolt Wrench size
M17V-07-048
: 41 mm
Tightening torque : 1400 N·m (140 kgf·m)
M17V-07-019
7-133
MAINTENANCE 20. Upper roller mounting bolt Wrench size
: 32 mm
Tightening torque : 750 N·m (75 kgf·m)
M17V-07-049
21. Lower roller mounting bolt Wrench size
: 36 mm
Tightening torque : 950 N·m (95 kgf·m)
M17V-07-050
22. Track shoe mounting bolt Wrench size
: 41 mm
Tightening torque : 2000 N·m (200 kgf·m)
M17V-07-051
23. Track guard mounting bolt Wrench size
: 41 mm
Tightening torque : 1400 N·m (140 kgf·m)
M17V-07-050
7-134
MAINTENANCE 24. Track mounting bolt Wrench size
: 55 mm
Tightening torque : 2800 N·m (280 kgf·m)
M17V-07-052
25. Flexible master coupling and T-bolt clamp of low pressure piping
Flexible master coupling of low pressure piping Wrench size
: 13 mm
Tightening torque : 11 to 13 N·m (1.1 to 1.3 kgf·m)
M1G6-07-008
T-bolt clamp Wrench size
: 11 mm
Tightening torque : 10 N·m (1.0 kgf·m)
M1J1-07-037
7-135
MAINTENANCE 26. Counterweight mounting bolt Wrench size
: 65 mm
Tightening torque : 2800 N·m (280 kgf·m)
MJAA-07-057
Counterweight retaining bolt Wrench size
: 36 mm
Tightening torque : 700 N·m (70 kgf·m)
MJAA-07-058
27. Signal control valve mounting bolt Wrench size
: 8 mm Hexagonal socket wrench
Tightening torque : 50 N·m (5.0 kgf·m)
M1J1-07-030
7-136
MAINTENANCE 28. Front pin securing bolt (backhoe) Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M1JB-07-003
Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M17V-07-009
M17V-01-005
Front pin retaining nut Wrench size
: 30 mm
Tightening torque : 400 N·m (40 kgf·m)
M162-06-032
7-137
MAINTENANCE 29. Fan mounting bolt Wrench size
: 10 mm Hexagonal socket wrench
Tightening torque : 90 N·m (9.0 kgf·m)
Fan drive coupling mounting nut Wrench size
: 24 mm
Tightening torque : 100 N·m (10 kgf·m) M1J7-07-049
30. Pilot pump mounting bolt Wrench size
: 8 mm Hexagonal socket wrench
Tightening torque : 50 N·m (5.0 kgf·m)
MJAC-07-009
31. Side branch piping bracket mounting bolt Wrench size
: 22 mm
Tightening torque : 140 N·m (14 kgf·m)
MJAA-07-100
32. Air compressor mounting bolt Wrench size
: 13 mm
Tightening torque : 25 to 30 N·m (2.5 to 3.0 kgf·m)
M1J1-07-083
7-138
MAINTENANCE Tightening Torque Chart Hexagon Wrench Bolt Dia. mm
Wrench size mm N·m (kgf·m)
N·m (kgf·m)
6 8 10 12 14 16 18 20 22 24 27 30 33 36
Socket Bolt
30 65 110 180 270 400 550 750 950 1400 1950 2600 3200
(3.0) (6.5) (11) (18) (27) (40) (55) (75) (95) (140) (195) (260) (320)
20 50 90 140 210 300 400 550 700 1050 1450 1950 2450
(2.0) (5.0) (9.0) (14) (21) (30) (40) (55) (70) (105) (145) (195) (245)
N·m (kgf·m) 3.3 to 4.2 (0.3 to 0.4) 10 (1.0) 20 (2.0) 35 (3.5) 55 (5.5) 80 (8.0) 120 (12) 170 (17) 220 (22) 280 (28) 400 (40) 550 (55) 750 (75) 950 (95)
CAUTION: If fixing bolts for counterweight are dloosened, consult your nearest authorized dealer. IMPORTANT: Apply lubricant (e. g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize their friction coefficient. Remove soil, dust, and/or dirt from the nut and bolt thread surfaces before tightening. Tighten nuts and bolts to specifications. If tightened with excessively low or high torque, missing or breakage of nuts and/or bolts may result.
7-139
Socket Bolt N·m
(kgf·m)
10 13 17 19 22 24 27 30 32 36 41 46 50 55
Wrench size mm 5
20 50 90 140 210 300 400
(2.0) (5.0) (9.0) (14) (21) (30) (40)
6 8 10 12 14 14 17
MAINTENANCE 1
Check O-rings in Bucket Check --- 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 O-ring (1) while referring to the separation type O-ring installation method described below.
1 1
M1JB-07-049
Type A (Separation Type O-ring) Installation Method 1. Install O-ring (1) in the direction as illustrated to the right so that the separation section of O-ring (1) does not directly come in contact with soil to protect O-ring (1) from being damaged quickly by soil or foreign matter.
1
2. Install O-ring (1) with care not to make a gap in the separation section of O-ring (1).
Separation Section
3. After installing O-ring (1), cut off the bolt extended from the nut so that O-ring (1) is not damaged by soil which may come in contact with the bolt.
Cut off the bolt extended from the nut.
1 Separation Type O-Ring
7-140
M1J1-07-074
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions Operating Conditions Muddy Soil, Rainy or After Operation Snowy Weather Near the Ocean After Operation
: :
Dusty Atmosphere
Air Cleaner Radiator Fuel System Engine, Muffler
: : : :
Rocky Ground
Tracks
:
Front Attachment :
Precautions for Maintenance Clean the machine and check for cracks, damaged, loose or missing bolts and nuts. Lubricate all necessary parts without delay. The following salt pollution measures must be taken when the machine is operated at sea or at coastline. (1) After completing the work, extend/retract the hydraulic cylinders several times to form oil film on the rod surface. Store the machine with cylinders retracted as much as possible. (2) Thoroughly clean the machine with fresh water to wash off salt. (3) Perform touch up painting periodically on hose fittings, lubrication piping and inserting position of cover, where sea water is easily collected, in order to prevent corrosion. (4) During storage of the machine, cover the machine by tarps to prevent sea water from entering into the cab vent. Apply rust prevention oil (example: ANTIRUST P-1300NP-3 JX Nippon Oil & Energy Corporation) onto plated part of the cylinder rods. Clean the element regularly at shorter service intervals. Clean the oil cooler screen to prevent clogging of the radiator core. Clean the filter element and strainer regularly at shorter service intervals. Clean earlier than the normal interval to prevent dust from sticking and accumulating. Inhibit regeneration according to the machine operating condition. Carefully operate while checking for cracks, damage and loose bolts and nuts. Loosen the tracks a little more than usual. Standard attachment may be damaged when digging rocky ground. Reinforce the bucket before using it, or use a heavy duty bucket. Provide a cab guard to protect the machine from falling stones. Consult your nearest Hitachi dealer.
Falling Stones
Cab Head Guard
:
Freezing Weather
Fuel/Lubricant Engine Coolant Battery
: Use high quality and low viscosity fuel and oil. : Be sure to use antifreeze. : Fully charge the batteries at shorter 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.
Track
9-1
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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.................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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9-2
STORAGE Storing the Machine In case the machine is to be stored for longer than one month, pay attention to the following points to prepare next operation. Precautions for Long-Term Storage Item
Remedy
Machine Cleaning
Wash the machine. Remove soil or other debris adhered to the machine.
Lubrication/Greasing
Check lubricant's level and contamination. Fill up or change if necessary. Lubricate all grease points. Coat grease to exposed metal surfaces which are subject to rust. (i.e. cylinder rods etc.)
Battery
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. If the machine is equipped with the battery disconnect switch (optional), turn the disconnect switch OFF.
Coolant
Add anti-rusting agent. If storing in extremely cold areas, either add extra anti-freeze or drain coolant completely to avoid freezing. In this case, place a sign reading "NO COOLANT".
Protection Against Dust and Moisture
Store the machine in a dry storage area using a protective cover.
Tools
Inspect and repair, then store.
Lubrication Operation
If oil film on the metal surfaces is lost, rust may begin, possibly causing abnormal wear of the machine when the machine operation is restarted. 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.
fNOTE: Lubricating operation is a series of warm-up, travel, swing and digging operation carried out repeatedly for a few cycles at slow speed. Lubricants will deteriorate during long term storage of the machine. Be sure to carefully check the lubricants before restarting operation of the machine. Precautions for Disconnecting or Connecting Batteries In case the batteries are kept disconnected for more than one month and/or the battery disconnect switch (optional) is turned OFF, data in the information controller or preset data of the radio may be initialized. Contact your nearest Hitachi dealer before restarting operation of the machine after the batteries are disconnected for one month or more.
10-1
STORAGE Removing the Machine From Storage CAUTION: d place.
Start the engine ONLY in a well-ventilated
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.
fNOTE:
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 Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Hitachi dealer. Never attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components. IMPORTANT: Never attempt to disassemble or modify the electrical/electronic components. Engine Consult the nearest Hitachi dealer for the engine troubleshooting. Engine Auxiliaries Problem Batteries will not be charged.
Cause Broken battery separator Faulty regulator Faulty ground line Faulty alternator Batteries discharges quickly after being Shorted cable charged. Shorted battery separator Increased sediment in battery Coolant temperature is too high. Low coolant level Damaged rubber hose Faulty thermostat Faulty coolant temperature gauge
Solution Replace * Adjust and replace * Repair * Repair or replace * Repair or replace * Repair or replace * Replace Refill * Replace * Replace * Replace *Mark: Consult your nearest Hitachi dealer.
11-1
TROUBLESHOOTING Impossible to Start the Engine Problem Starter does not rotate or is not powerful
Cause Discharged battery Disconnected, loose, or corroded battery terminals Lowered pilot control shut-off lever Disconnected, loose, or corroded starter ground line terminals
Engine will not start
Faulty pilot control shut-off lever electrical system Faulty Key Switch Faulty starter and/or electrical system Battery disconnect switch (optional) is OFF Starter rotates
No fuel Air in the fuel system Clogged fuel filter Blown fuse Malfunction of EC motor Engine stop switch is ON
Even though the engine is started, the engine stalls soon
Engine runs irregularly
Faulty preheat system Clogged fuel filter Contaminated injection nozzle Clogged feed pump strainer Blown fuse Faulty engine control system Clogged air cleaner Deteriorated engine oil Faulty fuel system Water or air in the fuel system Faulty engine control system
Solution Charge or replace battery. After repairing the corroded area, securely tighten the connectors. Pull pilot control shut-off lever up After repairing the corroded area, securely tighten the connectors. * Repair or replace * Replace * Repair, adjust or replace Move the switch to ON position. After checking that no fuel is leaking, refill fuel. Bleed air. Replace Replace * Repair, adjust or replace Move the switch to OFF position. * Repair, adjust or replace Replace * Replace Clean Replace * Repair, adjust or replace Clean or replace the element. Change engine oil * Repair, adjust or replace Drain water or bleed air. * Repair, adjust or replace
*Mark: Consult your nearest Hitachi dealer.
11-2
TROUBLESHOOTING Control Lever Problem Lever is heavy to operate.
Cause Rusted joint
Worn pusher Does not move smoothly Worn pusher Faulty pilot valve Does Not Return to Neutral Faulty pilot valve The lever is tilted in the neutral position Worn joint due to increase in play Faulty pilot valve
Solution * Lubricate or repair * Replace * Repair or replace * Replace * Replace * Repair or replace * Replace *Mark: Consult your nearest Hitachi dealer.
11-3
TROUBLESHOOTING Hydraulic System When the machine is stored without operation, air mixed in hydraulic oil will become separated and will accumulate in the cylinder upper sections, causing a delay in the response time of the machine movement or weak power development. In case these symptoms appear, repeatedly operate all actuators several times. Problem No hydraulic Functions (Noise from pumps)
Cause Faulty hydraulic pump Lack of hydraulic oil Broken suction pipe and/or hose No hydraulic Functions Faulty pilot pump (Hydraulic pump noise remains Faulty pilot shut-off solenoid valve unchanged.) Faulty wire harness (pilot shut-off solenoid valve) pilot shut-off switch The pilot control shut-off lever is in the LOCK position. All actuators have no power. Malfunction due to worn hydraulic pump Decreased main relief valve set pressure in the control valve Lack of hydraulic oil Clogged suction strainer in the hydraulic oil tank Absorption of air from the oil suction side Faulty pressure sensor Faulty solenoid valve Only one side lever is inoperable or has Faulty relief valve in the valve no power. Broken pipe and/or hose Loose pipe line joint Broken O-ring at pipe line joint Faulty hydraulic pump Faulty pilot valve Faulty pilot circuit line Faulty pilot solenoid valve
Solution * Repair or replace Refill * Repair or replace * Replace * Replace * Repair or replace Pull the pilot control shut-off lever to the UNLOCK position. * Replace * Adjust Refill Clean Retighten * Replace * Replace * Repair or replace * Repair or replace Retighten * Replace * Repair or replace * Replace * Repair or replace * Repair or replace
*Mark: Consult your nearest Hitachi dealer.
11-4
TROUBLESHOOTING Problem Only one actuator is inoperable.
Only one cylinder is inoperable or has no power.
Hydraulic oil temperature increases. Oil leak from low pressure hose
Cause Broken control valve spool Embedded foreign matter in valve spool Broken pipe and/or hose Loose pipe line joint Broken O-ring at pipe line joint Broken actuator Faulty pilot valve Faulty pilot circuit line
Solution * Replace * Repair or replace * Repair or replace Retighten * Replace * Repair or replace * Replace * Repair or replace
Faulty pilot solenoid valve Broken oil seal in cylinder Oil leak due to damage to cylinder rod Faulty pilot valve Faulty pilot circuit line
* Repair or replace * Repair or replace * Repair or replace * Replace * Repair or replace
Faulty pilot solenoid valve Stained oil cooler Loose clamps
* Repair or replace Clean Retighten
Faulty suction manifold
* Repair or replace *Mark: Consult your nearest Hitachi dealer.
11-5
TROUBLESHOOTING Drive Function Problem
Cause
Solution
One or both side tracks are inoperable. Damaged center joint Incompletely released parking brake Broken travel motor Faulty pilot valve Faulty pilot circuit line Does not travel smoothly. Overly tensioned or slackened crawler sag Lack of lubricant in front idler and/or roller Deformed track frame Embedded foreign matter such as rock fragments Dragged parking brake Travel speed does not change. Faulty travel mode switch Faulty pressure sensor Poor contact in connector Damaged wire harness Faulty controller (MC) Faulty solenoid valve Faulty motor
* Repair or replace * Repair or replace * Repair or replace * Replace * Repair or replace Adjust Refill * Repair or replace Remove * Repair * Replace * Replace * Repair or replace * Repair * Replace * Repair or replace * Repair or replace
*Mark: Consult your nearest Hitachi dealer.
11-6
TROUBLESHOOTING Swing Function Problem Upperstructure does not swing
Swing is not smooth
Cause
Solution
Faulty swing parking brake * Repair or replace Faulty swing parking brake release valve * Repair or replace Broken swing motor * Repair or replace Faulty pilot valve * Replace Faulty pilot circuit line * Repair or replace Worn swing gear * Repair or replace Damaged swing bearing and bearing balls * Repair or replace Lack of grease Refill *Mark: Consult your nearest Hitachi dealer.
Immediately after the control valve, swing motor relief valve and/or the swing motor is replaced, a noise may be emitted and/or operation may not be performed smoothly due to air trapped in the hydraulic line. Slowly continue to operate the machine for approx. 10 minutes to bleed air. After repair work is complete, be sure to check the oil level in the hydraulic oil tank. Refill hydraulic oil as needed.
11-7
TROUBLESHOOTING Engine Speed Problem
Cause
Even if operating the engine control dial, the engine speed does not change.
Solution
Blown fuse Faulty engine control dial Poor contact in connector Damaged wire harness (between EC dial and MC, or MC and ECM) Faulty controller (MC, ECM) Faulty EC motor Work mode does not change. Faulty mode switch Poor contact in connector Damaged wire harness (between MC and monitor) Faulty controller (MC) Faulty solenoid valve Auto-idle is inoperable or not released. Faulty pressure sensor Poor contact in connector Damaged wire harness Faulty controller.
Replace * Replace * Repair or replace * Repair * Replace * Repair or replace * Replace * Repair or replace * Repair * Replace * Repair or replace * Replace * Repair or replace * Repair * Replace
*Mark: Consult your nearest Hitachi dealer. Pump Control Problem Front attachment and/or travel speed is slow.
Cause Blown control fuse Poor contact in connector Damaged wire harness Faulty controller Faulty pump solenoid valve Faulty pressure sensor
Solution Replace * Repair or replace * Repair * Replace * Replace * Replace *Mark: Consult your nearest Hitachi dealer.
Others The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs. Always beware of the machine conditions during operation.
11-8
SPECIFICATIONS Specifications ZX470-5G, 470LC-5G
A C
G
L
B
F E
D K
J I
MJAC-12-001
H
Model Type of Front-End Attachment
ZX470-5G
ZX470LC-5G
-
3.4 m Arm
Bucket Capacity (Heaped)
m3
1.9 (1.7: CECE)
2.1 (1.8: CECE)
Operating Weight
kg
45600
46800
Base Machine Weight
kg
35700
Engine
36900
-
ISUZU AA-6WG1TQA 235 kW/1800 min (320 PS/1800 rpm) 3820
A:
Overall Width
mm
B:
Cab Height
mm
C:
Rear End Swing Radius
mm
-1
3170
3210 3660
D:
Minimum Ground Clearance
mm
*495
*535
E:
Counterweight Clearance
mm
*1230
*1270
F:
Engine Cover Height
mm
2790
2830
G:
Overall Width of Upperstructure
mm
H:
Undercarriage Length
mm
I:
Undercarriage Width
mm
J:
Sprocket Center to Idle Center
mm
K:
Track Shoe Width
mm
L:
Overall Height
Ground Pressure Swing Speed Travel Speed (fast/slow) Gradeability
fNOTE:
3480 5040
5470 3340
4040
4470 600 (Grouser shoe)
mm
3540
3580
kPa (kgf/cm2)
85 (0.87)
79 (0.81)
min-1 (rpm)
9.0
km/h
5.1/3.8
% (Degree)
70 (35)
*The dimensions do not include the height of the shoe lug.
12-1
SPECIFICATIONS Working Ranges ZX470-5G, 470LC-5G G
C
D
E
F A
B
MJAC-12-002
Backhoe
Model
ZX470-5G / ZX470LC-5G
ZX470LC-5G
7.0 m (Standard)
8.2 m
Boom Type Arm Type
2.9 m
3.4 m (Standard)
3.9 m
4.9 m
4.9 m
A: Maximum Digging Reach
(mm)
11400/11400
12060/12060
12490/12490
13260/13260
14430
B: Maximum Digging Depth
(mm)
7400/7360
7890/7850
8390/8350
9230/9190
10310
C: Maximum Cutting Height
(mm)
10130/10170
10920/10960
11040/11080
11420/11460
11980
D: Maximum Dumping Height
(mm)
6900/6910
7530/7570
7650/7690
8390/8430
8980
E: Overall Height
(mm)
*3850/3910
*3450/3730
*3490/3480
*4660/4660
*4530
F: Overall Length
(mm)
12130/12130
12050/12040
12050/12040
11850/11880
13150
G: Minimum Swing Radius
(mm)
5020/5020
4840/4840
4810/4810
4850/4850
5870
fNOTE:
*The dimension includes the height of the shoe lug. Other dimensions do not include the height of the shoe lug.
12-2
SPECIFICATIONS Specifications ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G A G
C
L
B F E D K
J I
MJAC-12-003
H
Model Type of Front-End Attachment
ZX470H-5G -
ZX470LCH-5G
ZX470R-5G
3.4 m H Arm
ZX470LCR-5G
3.4 m R Arm
Bucket Capacity (Heaped)
m3
Operating Weight
kg
46700
47800
46900
48100
Base Machine Weight
kg
36200
37400
36400
37600
Engine
1.9 (1.7: CECE)
-
ISUZU AA-6WG1TQA 235 kW/1800 min (320 PS/1800 rpm) 3820
-1
A:
Overall Width
mm
B:
Cab Height
mm
C:
Rear End Swing Radius
mm
D:
Minimum Ground Clearance
mm
*495
*535
*495
*535
E:
Counterweight Clearance
mm
*1230
*1270
*1230
*1270
F:
Engine Cover Height
mm
2790
2830
2790
2830
G:
Overall Width of Upperstructure
mm
H:
Undercarriage Length
mm
5040
5470
I:
Undercarriage Width
mm
J:
Sprocket Center to Idle Center
mm
4040
4470
K:
Track Shoe Width
mm
L:
Overall Height
Ground Pressure Swing Speed Travel Speed (fast/slow) Gradeability
fNOTE:
3280
3320
3280
3320
3660
3480 5040
5470 3340
4040
4470
600 (Grouser shoe)
mm
3540
3580
3540
3580
kPa (kgf/cm2)
87 (0.89)
81 (0.83)
87 (0.89)
82 (0.83)
min-1 (rpm)
9.0
km/h
5.1/3.8
% (Degree)
70 (35)
*The dimensions do not include the height of the shoe lug.
12-3
SPECIFICATIONS Working Ranges ZX470H-5G, 470LCH-5G, 470R5G, 470LCR-5G G
C
D
E
F A
B
MJAC-12-004
Backhoe
Model
ZX470H-5G / ZX470LCH-5G
ZX470R-5G / ZX470LCR-5G
Boom Type
7.0 m (H)
7.0 m (R)
Arm Type
3.4 m (H)
3.4 m (R)
A: Maximum Digging Reach
(mm)
12060
12060
B:
Maximum Digging Depth
(mm)
7900 / 7860
7900 / 7860
C:
Maximum Cutting Height
(mm)
10920 / 10980
10920 / 10980
D: Maximum Dumping Height
(mm)
7520 / 7560
7520 / 7560
E:
Overall Height
(mm)
3450
F:
Overall Length
(mm)
12050 / 12040
(mm)
4840
G: Minimum Swing Radius
fNOTE:
*The dimension includes the height of the shoe lug. Other dimensions do not include the height of the shoe lug.
12-4
SPECIFICATIONS Shoe Types and Applications (ZX470-5 class) ZX470-5G, 470H-5G, 470R-5G Grouser Shoe
Shoe Width Application
Base Machine Specifications
600 mm
750 mm
For Ordinary Ground (Standard)
For Weak Footing (Option)
Operating Weight
(kg)
45600
46300
Base Machine Weight
(kg)
35700
36400
Cab Height
(mm)
3170
3170
Minimum Ground Clearance
(mm)
*495
*495
Undercarriage Length
(mm)
5040
5040
Undercarriage Width
(mm)
3340
3490
85 (0.87)
69 (0.70)
Ground Pressure
kPa (kgf/cm ) 2
ZX470LC-5G, 470LCH-5G, 470LCR-5G Grouser Shoe
Shoe Width Application
Base Machine Specifications
600 mm
750 mm
For Ordinary Ground (Standard)
For Weak Footing (Option)
Operating Weight
(kg)
46800
47600
Base Machine Weight
(kg)
36900
37600
Cab Height
(mm)
3210
3210
Minimum Ground Clearance
(mm)
*535
*535
Undercarriage Length
(mm)
5470
5470
Undercarriage Width
(mm)
3340
3490
79 (0.81)
65 (0.66)
Ground Pressure
kPa (kgf/cm ) 2
fNOTE:
The specifications for the front-end attachment are for 3.4 m arm with (1.9 m3) and (2.1 m3) standard buckets. 750 mm and 900 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground may cause serious damage to shoe, shoe bolts and other parts such as rollers.
* The dimensions do not include the height of the shoe lug.
12-5
SPECIFICATIONS Bucket Types and Applications (ZX470-5 class) ZX470-5G Bucket Capacity (m3)
Bucket
Front-End Attachment
Bucket Width (mm)
ZX470-5G 7.0 m Boom
8.2 m Boom
Heaped PCSA (CECE)
Flat
With Side Cutters
2.9 m Arm
3.4 m Arm
3.9 m Arm
4.9 m Arm
4.9 m Arm
1.15 (1.0)
0.9
1210
*
*
*
1.4 (1.2)
1.0
1410
*
*
*
1.6 (1.4)
1.2
1360
*
*
1.9 (1.7)
1.4
1540
*
*
2.1 (1.8)
1.5
1630
*
*
2.3 (2.0)
1.7
1660
*
*
Hoe Bucket
ZX470LC-5G Bucket Capacity (m3)
Bucket
ZX470LC-5G 7.0 m Boom
8.2 m Boom
Heaped PCSA (CECE)
Flat
With Side Cutters
2.9 m Arm
3.4 m Arm
3.9 m Arm
4.9 m Arm
4.9 m Arm
1.15 (1.0)
0.9
1210
*
*
*
1.4 (1.2)
1.0
1410
*
*
*
1.6 (1.4)
1.2
1360
*
*
1.9 (1.7)
1.4
1540
*
*
2.1 (1.8)
1.5
1630
*
*
2.3 (2.0)
1.7
1660
*
*
Hoe Bucket
fNOTE:
Front-End Attachment
Bucket Width (mm)
: For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.) : For light duty excavating (digging and loading operation of dry, loosened earth, sand, mud and so on. The bulk density shall be less than 1600 kg/m3 as a standard.) : Not Applicable (Not Warrantable) * : Impossible to install
ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G Bucket Capacity (m3)
Bucket
Heaped (CECE)
Rock Bucket
1.9 (1.7)
Ripper Bucket One Point Ripper
fNOTE:
Bucket Width (mm) Flat
With Side Cutter
Front-End Attachment ZX470H-5G ZX470LCH-5G
ZX470R-5G ZX470LCR-5G
H Front
R Front
1.4
1480
1.3 (1.2)
1.0
1170 (Without side cutter)
-
-
-
: Rock digging (For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.)
12-6
SPECIFICATIONS Specifications ZX870-5G, 870LC-5G A
C
G
L
B
F E
D K
J I
Model Type of Front-End Attachment Bucket Capacity (Heaped) m3 Operating Weight kg Base Machine Weight kg Engine A: Overall Width mm B: Cab Height mm C: Rear End Swing Radius mm D: Minimum Ground Clearance mm E: Counterweight Clearance mm F: Engine Cover Height mm G: Overall Width of Upperstructure mm H: Undercarriage Length mm I: Undercarriage Width (Extended/ mm Retracted) J: Sprocket Center to Idle Center mm K: Track Shoe Width mm L: Overall Height mm Ground Pressure kPa (kgf/cm2) Swing Speed min-1 (rpm) Travel Speed (fast/slow) km/h Gradeability % (Degree)
MJAC-12-007
H
ZX870-5G
ZX870LC-5G
With 3.7 m (Std.) Arm 3.4 (3.0: CECE) 3.5 (3.1: CECE) 80800 82600 61100 62900 -1 ISUZU BB-6WG1XQA-04 360 kW/1800 min (490 PS/1800 rpm) 4450 3690 4600 *890 *1680 3630 4120 5840 6360 4100/3480 4590
5110 650 (Grouser shoe) 4290
121 (1.23)
112 (1.14) 7.4 4.5/3.0 70 (35)
f NOTE: *The dimensions do not include the height of the shoe lug.
12-7
SPECIFICATIONS Working Ranges ZX870-5G, 870LC-5G G
C
D
E
F A
B
MJAC-12-008
Backhoe
Model
ZX870-5G / ZX870LC-5G
Boom Type
8.4 m (Standard)
Arm Type
7.1 m (BE)
3.7 m (Standard)
4.4 m
2.95 m (BE)
A: Maximum Digging Reach
(mm)
14100
14910
12340
B: Maximum Digging Depth
(mm)
8870
9570
7140
C: Maximum Cutting Height
(mm)
13030
13820
12010
D: Maximum Dumping Height (mm)
9080
9740
8130
E: Overall Height
(mm)
*4770
*5130
*5200
F: Overall Length
(mm)
14800
14800
13550
G: Minimum Swing Radius
(mm)
5950
5950
5210
fNOTE:
*The dimension includes the height of the shoe lug. Other dimensions do not include the height of the shoe lug.
12-8
SPECIFICATIONS Specifications ZX870H-5G, 870LCH-5G, 870LCR5G A
C
G
L B
F
E D
K
J I
Model Type of Front-End Attachment
Bucket Capacity (Heaped) m3 Operating Weight kg Base Machine Weight kg Engine A: Overall Width mm B: Cab Height mm C: Rear End Swing Radius mm D: Minimum Ground Clearance mm E: Counterweight Clearance mm F: Engine Cover Height mm G: Overall Width of Upperstructure mm H: Undercarriage Length mm I: Undercarriage Width (Extended/ mm Retracted) J: Sprocket Center to Idle Center mm K: Track Shoe Width mm L: Overall Height mm Ground Pressure kPa (kgf/cm2) Swing Speed min-1 (rpm) Travel Speed (fast/slow) km/h Gradeability % (Degree)
fNOTE:
MJAC-12-009
H
ZX870H-5G
ZX870LCH-5G ZX870LCR-5G H Front R Front (with 3.7 m Arm) (with 3.7 m Arm) 3.4 (3.0: CECE) 3.5 (3.1: CECE) 3.5 (3.1: CECE) 82300 84200 85800 61800 63700 64000 -1 ISUZU BB-6WG1XQA-04 360 kW/1800 min (490 PS/1800 rpm) 4450 3800 4600 *890 *1680 3630 4120 5840 6360 6360 4100/3480 4590
124 (1.26)
*The dimensions do not include the height of the shoe lug.
12-9
5110 650 (Grouser shoe) 4290 115 (1.17) 7.4 4.5/3.0 70 (35)
5110
117 (1.19)
SPECIFICATIONS Working Ranges ZX870H-5G, 870LCH-5G, 870LCR-5G G
C
D
E
F A
B
MJAC-12-010
Backhoe
Model
ZX870H-5G, 870LCH-5G, 870LCR-5G
Boom Type
8.4 m (H, R)
Arm Type
3.7 m (H, R)
2.95 m (BE, BER)
7.1 m (BE, BER) 3.7 m (H, R)
A: Maximum Digging Reach
(mm)
14100
12340
12820
B: Maximum Digging Depth
(mm)
8870
7140
7820
C: Maximum Cutting Height
(mm)
13000
12010
12130
D: Maximum Dumping Height (mm)
9080
8130
8180
E: Overall Height
(mm)
*4770
*5200
*5000
F: Overall Length
(mm)
14800
13550
13510
G: Minimum Swing Radius
(mm)
5950
5210
5090
fNOTE:
*The dimension includes the height of the shoe lug. Other dimensions do not include the height of the shoe lug.
12-10
SPECIFICATIONS Shoe Types and Applications (ZX870-5 class) ZX870-5G, 870H-5G Grouser Shoe
Shoe Width
650 mm
750 mm
For Ordinary Ground (Standard)
For Weak Footing (Option)
(kg)
80800
81500
Application Operating Weight Base Machine Weight Base Machine Specifications
(kg)
61100
61800
Cab Height
(mm)
3660
3660
Minimum Ground Clearance
(mm)
*890
*890
Undercarriage Length
(mm)
5840
5840
Undercarriage Width (Extended/Retracted)
(mm)
4100/3480
4200/3580
121 (1.23)
106 (1.08)
Ground Pressure
kPa (kgf/cm2)
fNOTE:
The specifications for the front-end attachment are for (3.7 m) arm with (3.4 m3) (3.0 m3 CECE) bucket (heaped). Other than 650 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground may cause serious damage to shoe, shoe bolts and other parts such as rollers.
* The dimensions do not include the height of the shoe lug. ZX870LC-5G, 870LCH-5G, 870LCR-5G Grouser Shoe
Shoe Width Application
Base Machine Specifications
650 mm
750 mm
**900 mm
For Ordinary Ground (Standard)
For Weak Footing (Option)
For Weak Footing (Option)
Operating Weight
(kg)
82600
83300
84200
Base Machine Weight
(kg)
62900
63600
64500
Cab Height
(mm)
3660
3660
3660
Minimum Ground Clearance
(mm)
*890
*890
*890
Undercarriage Length
(mm)
6360
6360
6360
Undercarriage Width (Extended/Retracted)
(mm)
4100/3480
4200/3580
4350/3730
112 (1.14)
98 (1.00)
83 (0.84)
Ground Pressure
kPa (kgf/cm2)
fNOTE:
The specifications for the front-end attachment are for (3.7 m) arm with (3.5 m3) (3.1 m3 CECE) bucket (heaped). Other than 650 mm grouser shoe should not be used on gravel or rocky ground. Operating or digging on gravel ground may cause serious damage to shoe, shoe bolts and other parts such as rollers.
* The dimensions do not include the height of the shoe lug. ** Can not attach to ZX870LCH-5G, 870LCR-5G.
12-11
SPECIFICATIONS Bucket Types and Applications (ZX870-5 class) ZX870-5G Bucket Capacity Bucket Width (m3) (mm) Heaped Side Cutter Side Shroud PCSA Flat None Included (CECE)
Bucket
Hoe Bucket
fNOTE:
2.8 (2.5) 3.4 (3.0) 4.3 (3.8)
2.1 2.6 3.2
1550 1810 2040
1740 2000 2110
Bucket Teeth (qty.)
5 5 5
Weight (kg)
2570 2800 3770
Front-End Attachment ZX870-5G 7.1 m BE Boom 8.4 m Boom 2.95 m BE Arm
3.7 m Arm
4.4 m Arm
* * (Standard)
(Standard) *
(Standard) *
: For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.) : Not Applicable (Not Warrantable) * : Impossible to install
ZX870LC-5G Bucket Capacity (m3) Heaped PCSA Flat (CECE)
Bucket
Hoe Bucket
fNOTE:
*
2.9 (2.6) 3.5 (3.1) 4.5 (3.9)
2.2 2.6 3.4
Bucket Width (mm) Side Cutter Side Shroud None
Included
1590 1850 2120
1780 2040 2190
Bucket Teeth (qty.)
5 5 5
Weight (kg)
2700 2950 3970
Front-End Attachment ZX870LC-5G 7.1 m BE Boom 8.4 m Boom 2.95 m BE Arm
3.7 m Arm
4.4 m Arm
* * (Standard)
(Standard) *
(Standard) *
: For general excavating (digging and loading operation of sand, gravel, clay, ordinary earth and so on.) : Not Applicable (Not Warrantable) : Impossible to install
12-12
SPECIFICATIONS ZX870H-5G Bucket Capacity (m3)
Bucket
Rock Bucket
fNOTE:
Bucket Width (mm) Side Cutter Side Shroud
Heaped PCSA (CECE)
Flat
3.4 (3.0) 3.6 (3.2) 4.3 (3.8)
2.6 2.7 3.2
None
Included
1830 1910 2090
1850 1930 2110
Bucket Teeth (qty.)
Front-End Attachment ZX870H-5G Weight (kg)
7.1 m BE Boom 2.95 m BE Arm
5 5 5
3600 4060 4270
3.7 m H Arm
8.4 m H Boom 3.7 m H Arm
* (Standard) * (Standard) * * (Standard)
: Rock digging : Not Applicable (Not Warrantable) : Impossible to install
*
ZX870LCH-5G Bucket Capacity (m3)
Bucket
Rock Bucket
fNOTE:
*
Heaped PCSA (CECE)
Flat
3.5 (3.1) 3.7 (3.2) 4.3 (3.8)
2.6 2.8 3.2
Bucket Width (mm) Side Cutter Side Shroud None
Included
1870 1950 2090
1890 1970 2110
Bucket Teeth (qty.)
Front-End Attachment ZX870LCH-5G Weight (kg)
7.1 m BE Boom 2.95 m BE Arm
5 5 5
: Rock digging : Not Applicable (Not Warrantable) : Impossible to install
12-13
3790 3900 4270
3.7 m H Arm
8.4 m H Boom 3.7 m H Arm
* (Standard) * (Standard) * * (Standard)
SPECIFICATIONS ZX870LCR-5G Bucket Capacity (m3)
Bucket
Rock Bucket
fNOTE:
Heaped PCSA (CECE)
Flat
3.5 (3.1) 3.7 (3.2) 4.3 (3.8)
2.6 2.8 3.2
Bucket Width (mm) Side Cutter Side Shroud None Included
1870 1950 2090
1890 1970 2110
Bucket Teeth (qty.)
5 5 5
Weight (kg)
4870 4970 5690
Front-End Attachment ZX870LCR-5G 7.1 m BER Boom
8.4 m R Boom
2.95 m BER Arm
3.7 m R Arm
3.7 m R Arm
* * (Standard)
(Standard) *
(Standard) *
: Rock digging (For digging/loading operation of mountain gravels, blasted rock, hard clay, soft rock and so on.) : Not Applicable (Not Warrantable) * : Impossible to install
12-14
INDEX A Actual Operation........................................................................... 1-63 Adjust Bucket Linkage...............................................................7-107 Adjust Compressor Belt Tension.............................................. 7-92 Adjust the Operator’s Seat............................................................S-6 Adjusting Operator’s Seat (Air Suspension Type) (Optional)..................................................................................1-113 Adjusting Seat Height................................................................1-113 Adjusting the Seat.......................................................................1-111 After the First 100 Hours................................................................2-1 After the First 50 Hours..................................................................2-1 After Using Grease Gun............................................................... 7-38 Air Cleaner....................................................................................... 7-82 Air Conditioner.................................................................... 1-21, 7-89 Air Conditioner ON/OFF.............................................................. 1-21 Alarm Occurrence Screen........................................................... 1-15 AM/FM Radio Operation............................................................. 1-98 AM/FM Selector/Tuning Switch (Radio)................................ 1-75 Armrest Adjustment..................................................... 1-112, 1-114 Attachment...................................................................................... 5-35 Attachment Adjust........................................................................ 1-33 Attachment Name Input............................................................. 1-35 Attachment Operation................................................................ 1-59 Attachment Pedal (Hydraulic Breaker) (Optional)................5-3 Attachment Pedal (Hydraulic Crusher) (Optional)................5-4 Attachment Selection.................................................................. 1-23 Audio Input (Optional)..............................................................1-102 Audio Input Selection................................................................1-102 Auto Air Conditioner.................................................................... 1-90 AUTO/OFF Switch/Fan Switch (Air Conditioner)................ 1-74 Auto-Idle..............................................................................................5-8 Auto-Idle Switch............................................................................ 1-76 Auto-Lubrication Selector Switch (Optional) (6)................ 1-83 Auto-Lubrication Switch (5)....................................................... 1-83 Avoid Abusive Operation........................................................... 5-18 Avoid Applying Heat to Lines Containing Flammable Fluids............................................................................................ S-34 Avoid Hammer Work.................................................................... 5-17 Avoid Heating Near Pressurized Fluid Lines........................ S-34 Avoid High-Pressure Fluids........................................................ S-29 Avoid Injury from Back-Over and Swing Accidents.......... S-17 Avoid Injury from Rollaway Accidents................................... S-16 Avoid Power Lines......................................................................... S-21 Avoid Side Load the Bucket....................................................... 5-18 Avoid Tipping.................................................................................. S-19 Avoid Undercutting...................................................................... S-19 B BREAK-IN..............................................................................................2-1 Backrest Adjustment.................................................... 1-111, 1-114 Basic Screen........................................................................................1-7 Battery............................................................................................... 7-94 Battery Charger Operation........................................................ 7-33 Battery Disconnect Switch (Optional).................................... 7-11 Before Starting Engine...................................................................3-2 Beware of Asbestos and Silicon Dust and Other Contamination.......................................................................... S-35
Beware of Exhaust Fumes.......................................................... S-32 Bleed Air from the Fuel System................................................ 7-76 Bleed Air from the Hydraulic System..................................... 7-61 Boom Mode Switch (3)................................................................ 1-82 Breaker Operation......................................................................... 1-57 Brightness Adjustment................................................................ 1-45 Bucket Types and Applications (ZX470-5 class)................. 12-6 Bucket Types and Applications (ZX870-5 class)...............12-12 C COMPONENTS NAME......................................................................1-1 Cab Door Release Lever............................................................1-103 Cab Features (Std. Model).............................................................1-3 Cab Features (with Attachment).................................................1-4 Cab Heater Operation.................................................................. 1-94 Cab Light Switch............................................................................ 1-86 Change Bucket.............................................................................7-104 Change Coolant............................................................................. 7-86 Change Engine Oil, Replace Engine Oil Filter...................... 7-44 Change Hydraulic Oil................................................................... 7-58 Check Air Conditioner................................................................. 7-91 Check and Replace Bucket Teeth...........................................7-101 Check and Replace Injection Nozzle....................................7-114 Check and Replace Seat Belt...................................................7-108 Check at Preseason and Off-Season....................................... 7-93 Check Coolant Level..................................................................... 7-85 Check Cushion Rubber of Handrail (ZX470-5 class)........7-115 Check Engine Oil Level................................................................ 7-43 Check Fuel Hoses........................................................................... 7-81 Check Gas Damper.....................................................................7-115 Check Hoses and Lines................................................................ 7-67 Check Hydraulic Oil Level........................................................... 7-56 Check Instruments After Starting...............................................3-7 Check Looseness at Each of Fastened Areas....................... 7-92 Check of Fuel Injection Timing...............................................7-114 Check O-rings in Bucket ..........................................................7-140 Check Starter and Alternator..................................................7-114 Check the Hour Meter Regularly.................................................7-3 Check Track Sag...........................................................................7-110 Check Water Pump......................................................................7-114 Check Water Separator................................................................ 7-75 Check Windshield Fluid Level.................................................7-109 Cigar Lighter.................................................................................... 1-85 Circulation Air Mode.................................................................... 1-21 Clean Air Cleaner Element......................................................... 7-82 Clean Air Conditioner Condenser............................................ 7-88 Clean and Replace Air Conditioner Filter.............................. 7-89 Clean Cab Floor............................................................................7-113 Clean Feed Pump Strainer.......................................................... 7-80 Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Core .............................................................. 7-88 Clean Radiator, Oil Cooler and Inter Cooler (ZX870-5 class) Front Screen................................................ 7-88 Clock.................................................................................................. 1-11 Components Name...................................................1-1, 1-91, 7-32 Confirm Direction of Machine to Be Driven......................... S-13 Connecting Audio Device........................................................1-102
14-1
INDEX Console and Seat Fore-Aft Adjustment................. 1-112, 1-113 Control Lever (HITACHI Pattern) (Optional).............................5-2 Control Lever (ISO Pattern)...........................................................5-1 Controller Part Name and Function........................................ 1-92 Controls on the Radio.................................................................. 1-98 Cool Head/Warm Feet Operation............................................ 1-96 Coolant Temperature Gauge..................................................... 1-12 Cooling Operation........................................................................ 1-95 Cooling System.............................................................................. 7-84 Correct Maintenance and Inspection Procedures................7-1 D DRIVING THE MACHINE..................................................................4-1 Daily Check...................................................................................... 7-13 Date Adjustment........................................................................... 1-29 Date and Time................................................................................ 1-27 Default Setting..................................................................................1-6 Defroster Operation..................................................................... 1-96 Dig with Caution............................................................................ S-20 Display Item Selection (Rear View Camera OFF)................ 1-52 Display Mode Setting.................................................................. 1-31 Displaying Basic Screen.................................................................1-8 Dispose of Waste Properly.......................................................... S-37 Do Not Strike the Ground with Bucket Teeth...................... 5-17 Do Not Use Wide Track Shoes on Rough Ground.............. 5-19 Drain Fuel Tank Sump.................................................................. 7-74 Drive Machine Safely.................................................................... S-14 Drive the Machine Carefully.........................................................4-1 E ECO (Economy) Mode.................................................................. 1-77 Electric Grease Gun (Optional)................................................. 7-29 Electrical System............................................................................ 7-94 Emergency Exit............................................................................1-110 Engine................................................................................................ 7-43 Engine Control Dial....................................................................... 1-75 Engine Speed Control.....................................................................5-7 Engine Stop Switch (for Maintenance).................................. 1-88 Ensure Safety Before Rising from or Leaving Operator’s Seat............................................................................S-7 Evacuating in Case of Fire........................................................... S-32 Every 10 Hours or Daily..................................................................2-1 Extending Password Duration Time....................................... 1-14 F Fasten Your Seat Belt.......................................................................S-7 Fastening Machine for Transporting.........................................6-4 Features............................................................................................ 1-90 Flow Rate Adjustment................................................................. 1-33 Follow Safety Instructions.............................................................S-2 For Rapid Cooling.......................................................................... 1-97 Front Joint Pins............................................................................... 7-25 Fuel Gauge....................................................................................... 1-11 Fuel System...................................................................................... 7-72 Fuse Box............................................................................................ 1-89 Fuse Box 1........................................................................................ 1-89 Fuse Box 2........................................................................................ 1-89
G GETTING ON/OFF THE MACHINE................................................1-2 Getting ON/OFF the Machine......................................................1-2 General Precautions for Cab.........................................................S-5 Grading Operation........................................................................ 5-16 Grease Container Replacement............................................... 7-41 Greasing............................................................................................ 7-25 Greasing Method................................................................ 7-37, 7-39 H H/P (High Power) Mode.............................................................. 1-77 Handle (Emergency Engine Stop)........................................... 1-88 Handle Chemical Products Safely............................................ S-37 Handle Fluids Safely−Avoid Fires............................................ S-23 Height Adjustment.....................................................................1-111 Hood and Access Covers................................................................7-9 Horn Switch..................................................................................... 1-84 Hour Meter....................................................................................... 1-11 How to Lower Boom In Case of Emergency and When Engine Stops.............................................................................. 5-37 How to Use Screens.........................................................................1-8 Hydraulic Breaker and Hydraulic Crusher............................. 5-22 Hydraulic System........................................................................... 7-53 I Inclination Adjustment............................................... 1-112, 1-114 Information Menu......................................................................... 1-56 Input Password............................................................................... 1-13 Inspect and Adjust Valve Clearance......................................7-114 Inspect Machine...............................................................................S-4 Inspect Machine Daily Before Starting.....................................3-1 Inspection and Maintenance of Hydraulic Equipment.... 7-53 Install OPG Guard.......................................................................... S-12 Installation and Adjustment of Mirrors...............................1-115 Installing Fire Extinguisher (Optional)................................... 1-86 Installing/Removing Battery Pack........................................... 7-34 Investigate Job Site Beforehand.............................................. S-11 J Jump Starting....................................................................................S-9 K Keep Person Clear from Working Area.................................. S-18 Keep Riders off Machine................................................................S-9 Key Switch........................................................................................ 1-84 Kind of Oils....................................................................................... 7-21 L Language Settings........................................................................ 1-47 Layout...................................................................................................7-4 Lists of Display Language........................................................... 1-49 Loading/Unloading on a Trailer..................................................6-2 Lubricator (Optional).................................................................... 7-39 M MACHINE NUMBERS............................................................................1 MAINTENANCE..................................................................................7-1 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS . ..............................................................................9-1
14-2
INDEX Mail (Optional)................................................................................ 1-24 Main Menu....................................................................................... 1-20 Main Menu Sequence Change................................................. 1-54 Maintenance................................................................................... 1-65 Maintenance Guide...................................................................... 7-14 Maintenance Guide Table..............................................................7-6 Maintenance Notice..................................................................... 1-65 Maintenance Under Special Environmental Conditions....9-1 Measure Engine Compression Pressure..............................7-114 Miscellaneous...............................................................................7-101 Mode Switch........................................................................ 1-77, 5-14 Monitoring....................................................................................... 1-71 Move and Operate Machine Safely............................................S-8 Multi Function Monitor..................................................................1-5 N Never Position Bucket Over Anyone...................................... S-18 Never Ride Attachment............................................................... S-38 Never Undercut a High Bank..................................................... S-20 Normal Charging Method.......................................................... 7-34 Numeric Keypad............................................................................ 1-80 O OPERATING THE ENGINE................................................................3-1 OPERATING THE MACHINE............................................................5-1 OPERATOR’S STATION.....................................................................1-3 Object Handling............................................................................ S-22 Object Handling --- If Equipped............................................... 5-20 Observe Engine Operation Closely............................................2-1 Off-Season Air Conditioner Maintenance............................ 1-97 Opening Side Windows.............................................................1-107 Opening Upper Front Window...............................................1-105 Opening/Closing and Removing Cab Inside Window...1-104 Opening/Closing Overhead Window (Clear Hatch: If Equipped).................................................................................1-109 Opening/Closing Overhead Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)...........................................1-108 Opening/Closing Upper Front Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)...........................................1-105 Operate Only from Operator’s Seat...........................................S-8 Operate with Caution.................................................................. S-20 Operating Backhoe....................................................................... 5-15 Operating in Water or Mud...........................................................4-8 Operating on Soft Ground............................................................4-5 Operating Status Icon Display.................................................. 1-12 Operation......................................................................................... 1-57 P Park Machine Safely...................................................................... S-23 Parking the Machine.......................................................................4-9 Parking the Machine on Slopes...................................................4-9 Password Change.......................................................................... 1-37 Periodic Replacement of Parts.................................................. 7-20 Pilot Control Shut-Off Lever..............................................1-87, 5-5 Power Boost Switch........................................................... 1-84, 5-13 Power Source.................................................................................. 7-34 Power Switch/Volume Control Knob (Radio)...................... 1-75 Practice Safe Maintenance......................................................... S-25
Precaution for Arm Roll-In/Bucket Roll-In Combined Operation.................................................................................... 5-15 Precaution for Communication Terminal Equipment...... S-39 Precautions for After Operations............................................. 5-38 Precautions for Breaker Operation.......................................... 5-25 Precautions for Communication Terminal............................ S-38 Precautions for Crusher Operation......................................... 5-32 Precautions for Handling Accumulator and Gas Damper........................................................................................ S-34 Precautions for Lightning........................................................... S-21 Precautions for Operations........................................................ S-10 Precautions for Welding and Grinding.................................. S-33 Preparation for Using Electric Grease Gun........................... 7-36 Preparations for Inspection and Maintenance......................7-8 Prepare for Emergencies................................................................S-3 Prevent Battery Explosions........................................................ S-36 Prevent Burns.................................................................................. S-28 Prevent Fires.................................................................................... S-30 Prevent Parts from Flying........................................................... S-27 Protect Against Flying Debris................................................... S-22 Protect Against Noise.....................................................................S-4 Provide Signals for Jobs Involving Multiple Machines.... S-13 Pump Transmission (ZX870-5 class)........................................ 7-47 PWR (Power) Mode....................................................................... 1-77 R Radio.................................................................................................. 1-22 Raise One Track Using Boom and Arm.....................................4-6 Rear Light Switch (Optional) (2)............................................... 1-82 Rear View Camera Monitor (Optional)................................... 1-43 Rear View Camera ON/OFF........................................................ 1-43 Recognize Safety Information.....................................................S-1 Remedy............................................................................................. 1-17 Remove Paint Before Welding or Heating............................ S-35 Remove Travel Levers.................................................................7-108 Removing and Storing Lower Front Window....................1-106 Removing and Storing Lower Front Window (ZX470-5G, 470LC-5G, 870-5G, 870LC-5G)....................1-106 Removing the Machine From Storage................................... 10-2 Replace Air Breather Element................................................... 7-66 Replace Air Cleaner Outer/Inner Element............................ 7-82 Replace Fuel Main Filter.............................................................. 7-77 Replace Fuel Pre-Filter................................................................. 7-78 Replace Pilot Oil Filter.................................................................. 7-64 Replace Pump Drain Filter.......................................................... 7-63 Replace Rubber Hoses Periodically......................................... S-29 Replacement of Full-Flow Filter................................................ 7-62 Replacing Fuses............................................................................. 7-99 Retighten Cylinder Head Bolt.................................................7-114 Return to Basic Screen (Monitor)............................................. 1-74 Return to Previous Screen (Monitor)...................................... 1-74 S SAFETY.................................................................................................S-1 SAFETY SIGNS................................................................................. S-41 SPECIFICATIONS............................................................................. 12-1
14-3
INDEX STORAGE........................................................................................... 10-1 Seat Belt..........................................................................................1-116 Seat Depth Adjustment.............................................. 1-112, 1-114 Seat Fore-Aft Adjustment........................................... 1-111, 1-113 Seat Heater Switch (Optional) (7)............................................ 1-83 Security Functions........................................................................ 1-13 Select/Confirm Switch (Monitor)............................................. 1-74 Separation Type O-ring Installation Method.....................7-105 Separation Type O-ring Removal Method..........................7-104 Service Air Conditioning System Safely................................ S-36 Setting Menu.................................................................................. 1-26 Shoe Types and Applications (ZX470-5 class)..................... 12-5 Shoe Types and Applications (ZX870-5 class)...................12-11 Solid Type O-ring Installation Method.................................7-106 Solid Type O-ring Removal Method.....................................7-106 Specifications ZX470-5G, 470LC-5G....................................... 12-1 Specifications ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G.................................................................................. 12-3 Specifications ZX870-5G, 870LC-5G....................................... 12-7 Specifications ZX870H-5G, 870LCH-5G, 870LCR-5G......... 12-9 Starting the Engine..........................................................................3-3 Station Auto-Presetting Procedure.......................................1-100 Station Presetting Procedure.................................................... 1-99 Stay Clear of Moving Parts......................................................... S-27 Steering the Machine Using Levers...........................................4-3 Steering the Machine Using Pedals...........................................4-2 Stopping the Engine.................................................................... 3-10 Store Attachments Safely........................................................... S-28 Storing the Machine..................................................................... 10-1 Sub Meter......................................................................................... 1-41 Suction Filter Cleaning................................................................ 7-58 Support Machine Properly......................................................... S-26 Suspension Adjustment............................................................1-113 Swing Alarm Deactivation Switch (Optional) (4)............... 1-82 Swing Bearing................................................................................. 7-27 Swing Internal Gear...................................................................... 7-28 Swing Reduction Gear................................................................. 7-49 Switch Panel.................................................................................... 1-73 Switch Panel (for Optional Equipment)................................. 1-81
Travel Mode Switch..............................................................1-76, 4-4 Travel Operation............................................................................ 1-61 Travel Reduction Gear................................................................. 7-51 Troubleshooting................................................................. 1-69, 11-1 Tuning Procedure.......................................................................... 1-98 U Understand Signal Words..............................................................S-1 Unit Selection................................................................................. 1-50 Unloading...........................................................................................6-4 Use Correct Fuels and Lubricants...............................................7-3 Use Handholds and Steps.............................................................S-6 Using Booster Batteries..................................................................3-8 Using Cigar Lighter ...................................................................... 1-85 Using Cigar Lighter Port as External Power Source.......... 1-85 V Volume Control of Audio Device...........................................1-102 W Warming Up Operation..................................................................5-6 Warn Others of Service Work.................................................... S-26 Water Drain from Hydraulic Oil Tank...................................... 7-57 Wear Protective Clothing..............................................................S-3 Weight Adjustment....................................................................1-111 When Windows Become Clouded........................................... 1-97 Wiper/Washer Switch................................................................... 1-79 Work Light Switch......................................................................... 1-78 Work Mode........................................................................... 1-23, 5-10 Working Ranges ZX470-5G, 470LC-5G.................................. 12-2 Working Ranges ZX470H-5G, 470LCH-5G, 470R-5G, 470LCR-5G.................................................................................. 12-4 Working Ranges ZX870-5G, 870LC-5G.................................. 12-8 Working Ranges ZX870H-5G, 870LCH-5G, 870LCR-5G................................................................................12-10
T TRANSPORTING.................................................................................6-1 TROUBLESHOOTING..................................................................... 11-1 Temperature Control Switch/Mode Switch (Air Conditioner)............................................................................... 1-74 Tightening and Retightening Torque of Nuts and Bolts............................................................................................7-115 Time Adjustment........................................................................... 1-27 Time Remains and Maintenance Interval............................. 1-67 Tips for Optimal Air Conditioner Usage................................ 1-97 TONE Control................................................................................1-101 Towing Machine a Short Distance..............................................4-7 Transmission................................................................................... 7-47 Transport Safely............................................................................. S-24 Transporting by Road.....................................................................6-1 Travel Alarm (Optional)..................................................................4-4 Travel Alarm Deactivation Switch (Optional) (1)................ 1-82
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