Hitachi Zaxis 450-3 User manual

Serial No 20001 and up

PRINTED IN JAPAN (E) 2006, 01

This book is printed on recycled paper.

ZAXIS450-3 •470H-3 •450LC-3 •470LCH-3 •500LC-3 •520LCH-3 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL EM1J1-1-1

Hydraulic Excavator

PART NO. EM1J1-1-1

450-3

470H-3

450LC-3

470LCH-3

500LC-3

520LCH-3

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

0511D48ZX4504705001 2006.1.27,20:14:48

Hitachi Zaxis 450 470h 450lc 470lch 500lc 520lch 3 Series Operatior S Manual

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INTRODUCTION

Read this manual carefully to learn how to operate and

service your machine correctly. Failure to do so could re-

sult in personal injury or machine damage.

This manual should be considered a permanent part of

your machine and should remain with the machine when

you sell it.

This machine is of metric design. Measurements in this

manual are metric. Use only metric hardware and tools as

specified.

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

manual.

For reference MKS system units and English units are

also indicated in parentheses after the SI units.

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

Right-hand and left-hand sides are determined by facing

in the direction of forward travel.

Write product identification numbers in the Machine

Numbers section. Accurately record all the numbers to

help in tracing the machine should it be stolen. Your deal-

er also needs these numbers when you order parts. If this

manual is kept on the machine, also file the identification

numbers in a secure place off the machine.

Warranty is provided as a part of Hitachi’s support pro-

gram 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 war-

ranty period. In some circumstances, Hitachi also provides

field improvements, often without charge to the customer,

even if the product is out of warranty.

Should the equipment be abused, or modified to

change its performance beyond the original factory

specifications, the warranty will become void and field

improvements may be denied.

Setting fuel delivery above specifications or otherwise

overpowering machines will result in such action.

Only qualified, experienced operators officially licensed

(according to local law) should be allowed to operate

the machine. Moreover, only officially licensed personnel

should be allowed to inspect and service the machine.

All information, illustrations and specifications in this manual are based on the latest product information available at the

time of publication. The right is reserved to make changes at any time without notice.

MACHINE NUMBERS

The manufacturing Nos. explained in this group is the individ-

ual number (serial No.) given to each machine and hydraulic

components. These numbers are requested when inquiring

any information on the machine and/or components. Fill these

serial Nos. in the blank spaces in this group to immediately

make them available upon request.

MACHINE

MODEL/TYPE:

PRODUCT

IDENTIFICATION

NUMBER:

PRODUCT IDENTIFICATION NUMBER

PRODUCT

IDENTIFICATION

NUMBER:

NOTE:

ENGINE TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

TRAVEL MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M157-00-001

M111-07-010

M1J1-00-001

*HCM1J100P00020001*

PRODUCT IDENTIFICATION

NUMBER (PIN)

Marks to indicate the

start and end of the

M111-12-007

MACHINE NUMBERS

M16J-07-007

M1J1-001

SWING MOTOR TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

HYDRAULIC PUMP TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

BOOM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

ARM TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

M111-12-005

M17V-00-005

MACHINE NUMBERS

M116-12-004

BUCKET TYPE AND SERIAL NUMBER

TYPE:

MFG. NO.:

MACHINE NUMBERS

MEMO

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

CONTENTS

MACHINE NUMBERS

SAFETY

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

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

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

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

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

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

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

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

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

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

Ensure Safety Before Rising from or

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

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

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

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

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

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

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

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

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

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

Provide Signals for Jobs Involving

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Avoid Applying Heat to Lines Containing

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

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

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

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

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

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

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

SSAFETY SIGNS/Europe/Asia/Middle and

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

SAFETY SIGNS/North America and Oceania

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

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

OPERATOR’S STATION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Attachment Selection

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

Pump 2 Flow Rate Adjustment

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

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

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

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

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

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

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

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

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

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

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

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

CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Opening Upper Front Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-77

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

Removing and Storing Lower Front Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-79

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

Opening/closing Overhead Window

(ZAXIS450-3, 450LC-3, 500LC-3) .........................................1-80

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

Emergency Exit(ZAXIS450-3, 450LC-3, 500LC-3) .................1-81

Emergency Exit(ZAXIS470H-3, 470LCH-3, 520LCH-3) ........1-82

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

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

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

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

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

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

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

BREAK-IN

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

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

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

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

OPERATING the ENGINE

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

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

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

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

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

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

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

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

DRIVING the MACHINE

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

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

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

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

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

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

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

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

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

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

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

OPERATING the MACHINE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ASSEMBLING

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

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

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

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

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

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

Connecting Hoses Between Boom Cylinder and

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

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

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

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

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

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

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

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

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

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

ZAXIS450-3 (Backhoe) .................................................................6-20

CONTENTS

ZAXIS470H-3 (Backhoe) ..............................................................6-24

ZAXIS450LC-3 (Backhoe) ............................................................6-28

ZAXIS470LCH-3 (Backhoe) .........................................................6-32

ZAXIS500LCH-3 (Backhoe) .........................................................6-36

ZAXIS520LCH-3 (Backhoe) .........................................................6-40

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

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

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

MAINTENANCE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Inspection and Maintenance of Hydraulic

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Clean Radiator/ Oil Cooler/ Inter Cooler/

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

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

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

Clean and Replace Air Conditioner

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT

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

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

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

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

MAINTENANCE UNDER SPECIAL

ENVIRONMENTAL CONDITIONS

Maintenance Under Special Environmental Conditions .. 9-1

STORAGE

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

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

TROUBLESHOOTING

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

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

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

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

CONTENTS

SPECIFICATIONS

Specifications (Backhoe)

ZAXIS450-3, ZAXIS450LC-3, ZAXIS500LC-3 ....................12-1

Working Ranges (Backhoe)

ZAXIS450-3, ZAXIS450LC-3 ..................................................12-2

ZAXIS500LC-3 ..........................................................................12-3

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

ZAXIS450-3 ...............................................................................12-4

ZAXIS450LC-3 ..........................................................................12-4

ZAXIS500LC-3 ..........................................................................12-5

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

ZAXIS450-3, ZAXIS450LC-3 ..................................................12-6

ZAXIS500LC-3 ..........................................................................12-6

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

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ...........12-7

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

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ...........12-8

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

ZAXIS470H-3 ............................................................................12-9

ZAXIS470LCH-3 .......................................................................12-9

ZAXIS520LCH-3 .................................................................... 12-10

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

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ........ 12-11

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

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

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

OPTIONAL ATTACHMENTS and DEVICES

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

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

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

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

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

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

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

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

Three-way-valve Operation (Machines Equipped

with the Piping Common to Hydraulic Breaker

and Crusher Operation) ................................................... 13-14

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

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

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

Hitachi ZAXIS 450-3 User manual

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