Hitachi ZAXIS 850-3 Instruction manual

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




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 

SAFETY
SA-1
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 per-
sonal injury.
 Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
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 don't use any of the desig-
nated 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 indi-
cates a situation which, if not avoided, could result in
damage to the machine.
NOTE indicates an additional explanation for an
element of information.
002-E01A-1223
SA-1223

SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Shockless Valve
Group 12 Fan Motor
Group 13 Fan Valve
Group 14 Engine
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder

TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection

1JBW-1-1
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.............................................T1-1-1
Group 2 Tightening Torque
Tightening Torque Specification .............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
Periodic Replacement of Parts ............... W1-2-9
Group 3 Painting
Painting.................................................. W1-3-1
Group 4 Bleeding Air from Hydraulic Oil
Tank
Bleeding Air from Hydraulic Oil Tank....... W1-4-1

GENERAL / Precautions for Disassembling and Assembling
W1-1-1
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all disassem-bling
/ assembling procedures beforehand, to help avoid
incorrect disassembling of components as well as
personal injury.
Be sure to and record the items listed below to
prevent problems from occurring in the future.
 The machine model, machine serial number, and
hour meter reading.
 Reason for disassembly (symptoms, failed parts,
and causes).
 Clogging of filters and oil, water or air leaks, if
any.
 Capacities and condition of lubricants.
 Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
Precautions for Disassembling
 To prevent dirt from entering, cap or plug the
removed pipes.
 Before disassembling, clean the exterior of the
components and place on a work bench.
 Before disassembling, drain gear oil from the
reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling.
 Be sure to use the specified special tools, when
instructed.
 If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and
tag them as necessary.
 Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
 Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
 Measure and record the degree of wear and
clearances.

GENERAL / Precautions for Disassembling and Assembling
W1-1-2
Precautions for Assembling
 Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
 Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
 Before assenbling, coat all inner parts with clean
hydraulic oil or gear oil. Especially coat the sliding
surfaces with clean hydraulic oil or gear oil.
 Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
 Check that liquid-gasket-applied surfaces are
clean and dry.
 If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
 Utilize matching marks when assembling.
 Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
 Keep a record of the number of tools used for
disassembly / assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cyl-
inder is done, bleed air from the hydraulic system in
the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump
 Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
 After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
 Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
 After bleeding all the air, securely tighten the plug.
Bleeding Air from Travel Motor / Swing Motor
 With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

GENERAL / Precautions for Disassembling and Assembling
W1-1-3
Bleeding Air from Hydraulic Circuit
 After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
 Reposition the front attachment to check hydrau-
lic oil level.
 Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
M104-07-021

GENERAL / Precautions for Disassembling and Assembling
W1-1-4
Floating Seal Precautions
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with
seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks,
deformation or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
(2) Clean the floating seal and seal mounting
bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
W105-03-05-019
W105-03-05-020
W110-03-05-004
a b
b b
aa
a=b
C
A
B
IncorrectCorrect
Incorrect
Correct
A
B

GENERAL / Tightening Torque
W1-2-1
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Torque
No. Descriptions mm Qty Wrench
Size (mm) N m (kgf m) (lbf ft)
Front 27 2 41 1050 (105) (775)
1 Engine cushion rubbe
r
mounting bolt Rear 33 2 50 1950 (195) (1440)
Front 14 8 22 210 (21) (155)
2 Engine bracket mounting bolt Rear 20 12 30 400 (40) (295)
3 Radiator mounting bolt 27 4 41 1050 (105) (774)
4 Oil cooler mounting bolt 24 4 36 950 (95) (700)
5 Hydraulic oil tank mounting bolt 20 8 30 400 (40) (295)
6 Fuel tank mounting bolt 18 8 27 300 (30) (220)
7 ORS fittings for hydraulic hoses and piping
1
1
3
16
7
16
12UNF
12UNF
36
41
180
210
(18)
(21)
(135)
(155)
8 Pump transmission mounting bolt 12 14 19 110 (11) (80)
9 Pump device mounting bolt 20 4 2 17 hole 400 (40) (295)
10 Fan pump mounting bolt 16 4 14 hole 210 (21) (155)
11 Fan motor mounting nut 12 2 19 110 (11) (80)
12 Control valve mounting bolt 20 4 30 400 (40) (295)
13 Control valve bracket mounting bolt 20 8 30 400 (40) (295)
14 Swing device mounting bolt 24 14 2 36 950 (95) (700)
15 Swing motor mounting bolt 20 12 2 30 400 (40) (295)
16 Battery mounting bolt 12 2 19 35 (3.5) (25)
17 Cab mounting nut 16 6 24 210 (21) (155)
18 Swing bearing mounting bolt to upperstructure
Swing bearing mounting bolt to undercarriage
33
30
41
48
50
46
2200
1750
(220)
(175)
(1620)
(1290)
19
Travel device mounting bolt
Travel motor mounting bolt
Sprocket mounting bolt
27
18
27
24 2
4 2
24 2
41
27
41
1400
300
1400
(140)
(30)
(140)
(1030)
(220)
(1030)
20 Upper roller mounting 22 24 32 750 (75) (555)
STD, H 24 64 36 950 (95) (700)
21 Lower roller mounting bolt LC, LCH 27 72 36 950 (95) (700)
STD, H 27 376 41 2000 (200) (1475)
22 Track shoe bolt LC, LCH 27 408 41 2000 (200) (1475)
STD 27 16 41 1400 (140) (1030)
23 Track guard mounting bolt LC 27 36 41 1400 (140) (1030)
24 Track frame mounting bolt 36 44 55 2800 (280) (2065)
Flex Maste
r
Coupling 8 13 10.5 to12.5
(1.05 to
1.25)
(7.7 to
9.2) 25 Coupling and clamp of low
pressure piping Clamp 1/4-28 UNF 11 10 (1) (7.4)
26 Counterweight mounting bolt
Counterweight retaining bolt
45
24
2
4
65
36
2800
700
(280)
(70)
(2065)
(515)
27 Signal control valve mounting bolt 10 4 8 hole 50 (5) (37)
28 Front pin-retaining bolt
Front pin retaining bolt
20
20
24
7
30
30
400
400
(40)
(40)
(295)
(295)
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.

GENERAL / Tightening Torque
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or compo-
nents.
SA-040
W162-01-01-001
Specified Tightening Torque Chart
M552-07-091
Socket Bolt
M552-07-090
M552-07-092
Bolt Dia. Wrench
Size
Hexagon
Wrench
Size
N m (kgf m) (lbf ft) N m (kgf m) (lbf ft) N m (kgf m) (lbf ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
Socket Bolt
Hexagon M Bolt Hexagon H BoltHexagon T Bolt

GENERAL / Tightening Torque
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-
ternately, as shown, to ensure even tightening.
W105-01-01-003
1
6
4
2
3
Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally
1st to 4th
2nd to 3rd
13 11 10
14
12
7
6 1 4
3 2 58
9
5

GENERAL / Tightening Torque
W1-2-4
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tight-
ening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Nut and Bolt Locking
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight-
ening, not while loosening.
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
Bend along edge sharply Do not bend it round
Bend along edge sharply
Loosen
Tighten
WR
O
N
G
RIGHT RIGHT
RIGHT
WR
O
N
G
WR
O
N
G
RIGHT WR
O
N
G
WR
O
N
G
RIGHT
RIGHT

GENERAL / Tightening Torque
W1-2-5
PIPING JOINT
IMPORTANT: The torques given in the chart are
for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifi-
cations.
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
M202-07-051
W105-01-01-017
Wrench Size
mm
Wrench Size mm Tightening Torque
Description
Union Nut Hose Fittings N m (kgf m, lbf ft)
30 male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,21.5)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37 female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,21.5)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37 male coupling without union is similar
to tightening torque of 37 female.
37
30
Female Union JointMale Union Joint
13 5 2
Joint Body
4

GENERAL / Tightening
W1-2-6
O-ring Seal Joint
O-ring (6) seats against the end surface of adapter (7)
to seal pressure oil.
IMPORTANT: 1. Be sure to replace O-ring (6) with
a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly
in O-ring groove (8). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring
groove (8) or sealing surface
(10).
Damage to O-ring (6) will cause
oil leakage.
4. If nut (9) is loose and oil is leak-
ing, do not re-tighten nut (9). Re-
place O-ring (6) with a new one
and check that O-ring (6) is cor-
rectly seated in place, tighten nut
(9).
M104-07-033
Wrench Size
mm
Wrench Size
mm
Tightening Torque
Union Nut Joint Body N m (kgf m, lbf ft)
19 17 29.5 (3.0,21.5)
22 19 69 (7.0,51)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 30,32 175 (18.0,129)
41 36 205 (21.0,151)
46 41 205 (21.0,151)
7 6 9
8 1
Joint Body

GENERAL / Tightening
W1-2-7
Screw-In Connection
Depending on types of screw and sealing, different
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Seal Tape Application
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
Application Procedure
Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp:
4.4 N m (0.45 kgf m, 3.25 lbf ft)
Worm Gear Type Band Clamp:
5.9 to 6.9 N m (0.6 to 0.7 kg m, 4.3 to 5.1 lbf ft)
W105-01-01-018
Male Tapered Thread
Wrench Size
mm
Tightening Torque
N m (kgf m, lbf ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
W105-01-01-019
M114-07-041
M114-07-043 M114-07-042
PF
30
PT
Male Straight ThreadMale Tapered Thread
Clearance
External Thread
Internal Thread
Leave one to two pitch threads uncovered
T-Bolt Type Worm Gear Type

GENERAL / Tightening
W1-2-8
Connecting Hose
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print
marks on hoses when installing to prevent
hose from being kinked.
If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other.
Take care so that hoses do not come into
contact with moving parts or sharp objects.
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014
Rubbing Against
Each Other
RIGHT
RIGHT
RIGHT
RIGHT
WR
O
N
G
WR
O
N
G
WR
O
N
G
WR
O
N
G
Rubbing Against
Each Other
Rubbing Against
Each Other
Clamp
Clamp
Clamp

GENERAL / Tightening
W1-2-9
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine
ages and are worn out or fatigued by repeated loads,
resulting in possible severe personal injury and/or
machine trouble. The service life of these parts can-
not be detected through machine operation or visual
inspection.
Therefore, these parts should be replaced at regular
intervals even if no abnormalities are noticed. In case
any abnormalities are found on a part at any time
regardless of its specified replacement interval, im-
mediately replace the part.
Periodic Replacement Parts Replacement
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or 6000 hours
Fuel hose (Fuel tank to injection pump) Every 2 years or 6000 hours
Engine
Heater hose (Heater to engine) Every 2 years or 6000 hours
Pump suction hose Every 2 years or 6000 hours
Pump delivery hose Every 2 years or 6000 hours
Swing hose Every 2 years or 6000 hours
Basic Machine
Travel hose Every 2 years or 6000 hours
Boom cylinder line hose Every 2 years or 6000 hours
Arm cylinder line hose Every 2 years or 6000 hours
Bucket cylinder line hose Every 2 years or 6000 hours
Pilot hose Every 2 years or 6000 hours
Hydraulic
System
Front-End
Attachment
Seat Belt Every 3 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.

GENERAL / Painting
W1-3-1
PAINTING
Painting specification
Surfaces to Be Painted Painting Colour
 Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Bed cover HG Beige Deep
Inner Grey
Front left step, center, rear left step HG Beige Deep
Counterweight YR-01 [TAXI yellow]
Handrail HG Beige Deep
 Front attachment YR-01 [TAXI yellow]
 Track (including swing ring) N1.0 [Black]
 Floor plate M/F Cation (allowed)
Final painted color
 Inside and outside surface of cab HG Beige Deep
 Shaded area on cab outside Shining Silver
 Right window beam, U-Bolt [KANSAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
 Suspension lifter (chair bottom) [N2.0 (Black)]
 Lever (travel, pilot shut-off, foot rest) High Grade Brack
 Nonslip cover KANSAI PAINT AMYLAC 1400 (Deep Black)
 Mirror stay High Grade Brack
 Rear camera assembly HG Beige Deep, HG Brack
Specified masked position
 Engine plate
 Control valve plate  Cover catch, door handle
 Swing motor plate  Battery cable terminal cover
 Pump plate  Air cleaner
 Fan pump plate  Fan motor plate
 Muffler [including U-bolt]  Atmospheric pressure [battery space]

GENERAL / Painting
W1-3-2
W1JB-01-03-001
Section A
Swing Device
(TAXI Yellow)
Handrail
(HG Beige Deep) * (Refer to W1-3-5.)
A
Front Step including Handrail
(HG Beige Deep)
Tread Center Walk
Inside (Grey)
Tread Center Walk Front of Engine Cover
(TAXI Yellow (Shaded Area)
Rear Step
(HG Beige Deep)
Center Step
(HG Beige Deep)
* (Refer to W1-3-5.)