Hitachi ZAXIS 850-3 Instruction manual

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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.