Hitachi Zaxis 800 850H Hydraulic EXcavator Technical Assembly Procedure Manual by www.heydownloads.com

KO-282-00

TEMPORARY

ASSEMBLY PROCEDURE MANUAL

Foreword Assembly work is the final touch that gives the machine life. The quality of a machine's assembly affects its operative performance and service life of the machine. Because a machine's value is determined by its assembly, those who do this work are required to have sufficient know-how about assembly. This manual basically contains assembly know-how such as methods and useful hints for assembling the ZX800/ZX850H Hydraulic Excavator. Please read this manual carefully and try to keep it for reference before you engage in assembly or while you work. This manual is a practical compilation of the following three viewpoints: "the improvement of work safety", "the improvement of efficiency" and "the enhancement of product quality." 1) Safety:

Some hints and information for safe work are provided, such as the weight of the parts, their lifting points when raised with wire ropes and their handling procedures. Work safety is attained with this manual.

2) Quality:

Procedures and hints are described for correct machine assembly. They include the part numbers, tightening torque values of bolts, etc. Correct assembly is essential to provide the machine with a longer service life at maximum performance.

3) Efficiency:

Tool jigs, the facilities necessary to do the work and the preparation needed for each work stage are introduced to assure speedy and effective completion.

We hope this manual will be helpful to you in assembling the machine without a hitch.

ZX800/ ZX850H Assembly Chart BACKHOE FRONT

ii Weight: ZX800 - 73 900 kg (162 900 lb) / ZX850H - 75 900 kg (167 000 lb) 3.6 m (H Arm) 3.6 m (H Arm) 3.4 m3 (Bucket) 3.4 m3 (Bucket)

ZX800/ ZX850H Assembly Chart BACKHOE FRONT

iii Weight: ZX800 - 73 900 kg (162 900 lb) / ZX850H - 75 900 kg (167 000 lb) 3.6 m (H Arm) 3.6 m (H Arm) 3.4 m3 (Bucket) 3.4 m3 (Bucket)

ZX800/ ZX850H Assembly Chart LOADER FRONT

iv Weight: ZX800 4.0 m3 (5.23 yd3) Standard Bottom Dump Bucket 77 700 kg (171 300 lb)

Weight: ZX850H 4.4 m3 (5.75 yd3) Standard Tilt Dump Bucket 76 700 kg (169 100 lb)

3.6 m3 (4.71 yd3) Bottom Dump Lock Bucket 78 400 kg (172 800 lb)

4.0 m3 (5.23 yd3) Tilt Dump Lock Bucket 77 300 kg (170 400 lb)

ZX800/ ZX850H Assembly Chart LOADER FRONT

v Weight: ZX800 4.0 m3 (5.23 yd3) Standard Bottom Dump Bucket 77 700 kg (171 300 lb)

Weight: ZX850H 4.4 m3 (5.75 yd3) Standard Tilt Dump Bucket 76 700 kg (169 100 lb)

3.6 m3 (4.71 yd3) Bottom Dump Lock Bucket 78 400 kg (172 800 lb)

4.0 m3 (5.23 yd3) Tilt Dump Lock Bucket 77 300 kg (170 400 lb)

CONTENTS Page 1.

Precautions ………………………………………………………………………………………………………………1 1-1.

Safety precautions for servicemen ……………………………………………………………………………1

1-2.

How to use a power wrench ……………………………………………………………………………………14

1-3.

Work precautions ………………………………………………………………………………………………17

Work Plan and Preparations…………………………………………………………………………………………27 2-1.

Work Plan (Backhoe Front) ……………………………………………………………………………………27

2-2.

Work Plan (Loader Front) ………………………………………………………………………………………28

2-3.

Transportation……………………………………………………………………………………………………29

Parts check ……………………………………………………………………………………………………………47 3-1.

Check ……………………………………………………………………………………………………………47

Preparations ……………………………………………………………………………………………………………48 4-1.

Preparations (Backhoe front) …………………………………………………………………………………48

4-2.

Preparations (Loader front) ……………………………………………………………………………………49

Machines, apparatuses, tools, and materials necessary for assembly ……………………………………50

Assembly of superstructure…………………………………………………………………………………………59

6-1.

Preparation ………………………………………………………………………………………………………59

6-2.

Connecting the side frames to the track frame ………………………………………………………………62

6-3.

Mounting the counterweight ……………………………………………………………………………………78

6-4.

Greasing of swing bearing ……………………………………………………………………………………82

6-5.

Final check of superstructure …………………………………………………………………………………84

6-6.

Releasing the air from the main pumps ………………………………………………………………………87

6-7.

Trial operation of superstructure ………………………………………………………………………………88

Backhoe front mounting procedure ………………………………………………………………………………93 7-1.

Preparation ………………………………………………………………………………………………………93

7-2.

Mounting the backhoe front ……………………………………………………………………………………95

7-3.

Bleeding the cylinders and checking the hydraulic system ………………………………………………130

7-4.

Adjusting the track link tension ………………………………………………………………………………132

7-5.

Final trial operation check ……………………………………………………………………………………134

7-6.

Backhoe lubrication ……………………………………………………………………………………………135

Loader front mounting procedure ………………………………………………………………………………141 8-1.

Preparation ……………………………………………………………………………………………………141

8-2.

Mounting the loader front ……………………………………………………………………………………143

8-3.

Bleeding the cylinders and checking the hydraulic system ………………………………………………170

8-4.

Adjusting the track link tension ………………………………………………………………………………172

8-5.

Final trial operation check ……………………………………………………………………………………174

8-6.

Loader lubrication………………………………………………………………………………………………175

Extending and retracting the side frames ………………………………………………………………………179

10. Checks after completing the assembly …………………………………………………………………………191 11. Checking machine performance …………………………………………………………………………………193 12. Appendix (Lifting Diagrams) ………………………………………………………………………………………203 12-1. Assembly Instructions Appendix (Right bracket) …………………………………………………………205 12-2. Assembly Instructions Appendix (Left bracket) ……………………………………………………………207 12-3. Superstructure lifting jig ………………………………………………………………………………………209

1. Precautions 1-1 Safety precautions for servicemen

RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.

Fig. 1-1

UNDERSTAND SIGNAL WORDS Machine safety signs incorporate signal words DANGER, WARNING and CAUTION - to designate the degree or level of hazard. DANGER indicates an imminently hazardous situation which, if not avoided, will potentially 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. Fig. 1-2

DANGER and WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety items in this manual. To avoid confusing machine protection with personal safety messages, IMPORTANT is used to indicate a situation which, if not avoided, could result in damage to the machine.

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 Hitachi dealer in the same way as you order other replacement parts (be sure to state the machine model and serial number when ordering.)

Fig. 1-3

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 to the machine may impair its functions and/or safety, and affect machine life. The safety messages in this chapter are intended to illustrate basic safety procedures for hydraulic excavators. 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 before operating or performing maintenance work on the machine.

DESIGNATE ONE LEADER AND TWO SUBLEADERS In order to work with the greatest safety and ease, designate a foreman and two subleaders as working partners. When assembling the superstructure, station the subleaders at the front and rear of the machine. They should carry out and follow the leader's signals with utmost care to avoid breakage of components and personal injury. Fig. 1-4

CLEAN THE MACHINE REGULARLY Remove any grease, oil or dirt build-up to avoid possible injury or machine damage. Do not spray water or steam inside the cab.

Fig. 1-5

WEAR PROTECTIVE CLOTHING Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Wear close fitting clothing and safety equipment appropriate to the job. You may need: • A hard hat • Safety shoes • Safety glasses, goggles, or a face shield • Heavy gloves • Hearing protection • Reflective clothing • Wet weather gear • Respirator or filter mask.

Fig. 1-6

PREPARE FOR EMERGENCIES Be prepared for the eventuality of a fire. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, a hospital, and the fire department near your telephone.

Fig. 1-7

PREPARE SUITABLE LIFTING TOOLS Work with this machine involves lifting heavy and bulky items with a crane. Pay attention to the following points: a) Prepare suitable lifting tools. b) To prevent unnecessary mishaps due to broken wire cables, do not use damaged chains or frayed cables, slings, or ropes. Be sure to use a proper protector and patch. c) Before proceeding with the work, agree on specific signals with the crane operator and the designated leader/subleader team. d) Always keep the area directly below any load clear of people during slinging work. e) Service personnel and mechanics must check the weights given in this manual, and apply the proper lifting procedures when removing any components. f) When using hydraulic excavators for lifting operations, be sure to comply with all local regulations.

Fig. 1-8

ENGINE SAFETY a) No one should be allowed inside the hydraulic excavator while it is being operated or during assembly. b) Keep hands away from moving parts. c) Sound the horn as an alert to those nearby before starting up the engine. d) Start the engine from the operator's seat and never while standing on the ground. e) To avoid injury or possible machine damage, never start the engine by shorting across the starter terminals.

Fig. 1-9

SUPPORT RAISED EQUIPMENT Never work under or near a raised bucket. Lower the bucket to the ground or onto secure blocks.

Fig. 1-10

SAFETY AT HEIGHT Take adequate measures to avoid falling from high spots during work. Clean any mud or debris from the steps, walkways, or work platforms before work, and use a safety belt during work. 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 handholds. Before getting off, be sure to align the cab parallel with the tracks. 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 getting off the machine.

Fig. 1-11

FUEL SAFETY AND FLAMMABLE MATERIALS a) Never smoke while refueling or handling flammable materials. b) Shut the engine off while refueling. c) Exercise caution when refueling while the engine is still hot. d) Do not clean parts using opened cans of gasoline or diesel fuel. Use good, commercial, nonflammable solvents.

Fig. 1-12

PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of the battery. Battery gas can explode. Never check the 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 16Â°C (60.8Â°F). Disconnect the negative ground cable before working on the electrical system or making major repairs. Fig. 1-13-1

Fig. 1-13-2

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. Relieve the pressure by moving the control levers several times. Tighten all connections before pressurizing the hydraulic system. • Search for leaks with a piece of cardboard, taking care to protect your hands and body from highpressure fluids. Wear a face shield or safety 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.

Fig. 1-14-2

Fig. 1-14-1

Fig. 1-14-3

Fig. 1-14-4

CHECK EQUIPMENT SAFETY a) Use a piece of cardboard or paper to safely check for leaks in all systems, including the following: Hydraulic system Fuel system b) Use the correct testing gauge type when checking the hydraulic pressure. c) Check all protective parts on the machine (shields, guards, pins, etc.). They should be in good condition and securely fastened. d) Inspect electrical wiring for worn or frayed insulation, and install new wiring if damage has occurred.

Fig. 1-15

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 uncomfortable loud noises.

Fig. 1-16

FASTEN YOUR SEAT BELT Prior to operating the machine, thoroughly examine the belt, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component in question before operating the machine. Be sure to remain seated with seat belt securely fastened at all times when the machine is in operation.

Fig. 1-17

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 fresh air into the area.

Fig. 1-18

PRACTICE SAFE MAINTENANCE Understand service procedures before performing any work. Keep the work area clean and dry. Never lubricate or service the machine while it is moving. Keep hands, feet and clothing away from power-driven parts. Before servicing the machine. • • • • • • • • • •

Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle switch off. Run the engine at slow idle speed without load for 3 minutes. Turn the ignition OFF to stop the engines. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the ignition. Attach a "Do Not Operate" tag to the travel speed select/pilot control shut-off lever Set the travel speed select/pilot control shut-off lever to the P position. Allow the engine to cool.

Fig. 1-19-1

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. Never work under a machine raised by the boom. Inspect certain parts periodically, and repair or replace as necessary. Refer to the relevant section of the Operation Manual. Keep all parts in good condition and properly installed. Fix any damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris. Disconnect the battery ground cable (-) before making adjustments to the electrical system or performing welding work on the machine.

Boom Arm

90 to 110°

Fig. 1-19-2

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 to the travel speed select/pilot control shut-off lever. This tag is available from your authorized dealer.

Fig. 1-20

AVOID HARMFUL ASBESTOS DUST Avoid breathing in dust generated from the handling of components containing asbestos fiber. Inhaled asbestos fiber may cause lung cancer. Components that potentially contain asbestos fiber are certain types of gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding asbestoscontaining materials. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean away asbestos. If not available, wet the asbestos-containing materials with a mist of oil or water. Be sure to comply with all applicable rules and regulations for the work place. Follow all local environmental rules and regulations for the disposal of asbestos.

Fig. 1-21

Keep bystanders away from areas where asbestos particles may be in the air.

PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris - wear goggles or safety glasses. In order to avoid personal injury, keep bystanders away from the working area when striking any object.

Fig. 1-22

PREVENT AGAINST FLYING PARTS Grease in the track adjuster is under high pressure. Do not attempt to remove a GREASE FITTING or VALVE ASSEMBLY. Be sure to keep your body and face away from any valve, as pieces may fly off. The travel reduction gears are under pressure. So as to avoid injury from flying parts, be sure to keep your body and face away from the AIR RELEASE PLUG. GEAR OIL is hot. Wait for the GEAR OIL to cool, then gradually loosen the AIR RELEASE PLUG to release pressure.

PREVENT BURNS Hot spraying fluids: • After operation, the engine coolant is hot and under pressure. Also, hot water or steam is contained in the engine, radiator and heater lines. Prevent 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 position. Allow all pressure to release before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: • Skin contact with escaping hot water or steam can cause severe burns. Be sure to stop the engine, and let the engine and radiator cool. Once the system has cooled, slowly loosen the radiator cap to release pressure, then remove it. • Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts also become hot. Wait for the oil and components to cool before starting any maintenance or inspection work.

Fig. 1-23

Fig. 1-24-1

Fig. 1-24-2

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 them falling. Keep playing children and bystanders away from the storage area.

Fig. 1-25

DISPOSE OF WASTE PROPERLY Improper waste disposal 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.

Fig. 1-26

Allowing air conditioning refrigerants to escape 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 as to the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your HITACHI dealer.

SERVICE THE AIR CONDITIONING SYSTEM SAFELY Refer to the outside of the freon container for proper handling procedures when servicing the air conditioning system. Use a recovery and recycling system to avoid venting freon into the atmosphere. Never let the freon stream make contact with your skin. Severe frost burns will result.

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, paint, and adhesives.

Fig. 1-27

HANDLE POWER WRENCHES CORRECTLY Misuse of power wrenches (part nos. 4093800 and 4229414) may lead to their breakage or personal injury. Please use power wrenches correctly and in accordance with this manual. 1

For your safety, do not enter into the turning circle of the wrench. After tightening is complete, a torque acting in the opposite direction will be applied to the wrench. Therefore, do not suddenly let go of the handle, but let it gently rotate back in the opposite direction until the torque is zero.

Fig. 1-28

Excessive input torque may cause the output end or reaction lever to break, causing the wrench to fall from the machine. The wrench may also fall if it slips off the reaction member. Secure the wrench so that it cannot drop, especially when working on vertical surfaces.

Fig. 1-29

Fig. 1-30

It is sometimes difficult to remove the power wrench from a nut or bolt after tightening.This is generally due to elastic deformation (elastic force) between the wrench and bolt. Try changing the clutch direction to L to make the wrench easier to remove. Release the torque on the ratchet handle gradually, since a force will be acting in the opposite direction after changing over the clutch. If it is not possible to change the clutch by hand, do not attempt to use force (a hammer, etc.).

Fig. 1-31

â&#x20AC;˘ Try turning the wrench handle slightly in the L direction to make the clutch easier to change over. 1

Fig. 1-32

COMMUNICATION 1

When slinging work is performed on heavy loads, a predetermined hand signalling method should be used for trouble-free communication.

In order to facilitate remote teamwork during assembly, workers should wear headsets for reliable communication.

Fig. 1-33

COMPONENT NAMES

1 2 3 4 5 6 7

Bucket Bucket Cylinder Arm Arm Cylinder Boom Cylinder Boom Fuel Tank

8 9 10 11 12 13 14

Hydraulic Oil Tank Engine Counterweight Travel Device Track Front ldler Cab

7 8

9 14

13 10

12 Fig. 1-34

1-2 How to use a power wrench This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench should be preferred over a power wrench, for reasons of safety and overall quality.

METHOD OF USE

4. Input direction selection on the

1. Socket selection and mounting.

The input direction is set by using

Select the socket which fits most

the changeover lever on the

snugly onto the bolt, and mount the

ratchet handle.

socket on the wrench. Secure the socket to the wrench with a 38.1

Changeover lever

mm pin or 25.4 mm bolt.

Fig. 1-39 5. Changeover clutch.

Fig. 1-35

Changeover clutch

Select the input direction by setting the changeover clutch as detailed in the figure to right (Fig. 1-40).

2. When accurate torque control is required. Set the torque according to the input/output diagram in Fig. 1-49 (page 16). (Output = input x gear ratio x efficiency)

Fig. 1-40 6. Completion of work.

Fig. 1-36

On completion of tightening, remove the wrench from the nut or

3. Check the positioning of the reaction lever. Depending upon the wrench type the reaction lever usually acts radially. Due to the large reaction force applied to the reaction lever, the reaction lever should be positioned so that it is both secure and stable.

bolt. Elastic deformation (force)

between the wrench and bolt can make it difficult to remove the

power wrench. In this case, gradually release the torque on the ratchet handle and change over the clutch direction.

Fig. 1-41

Straight type reaction lever

Fig. 1-37 When using an "L-type" torque wrench, make sure that the distance "L" between the center of the bolt and support point is at least the figures shown below. Failing to observe this minimum distance can damage or break the bolt, or cause the output shaft to become jammed.

Clutch selection L (counter clockwise)

L type reaction lever

R (clockwise) Model

8-150P

110

8-300P

130

12-450P

145

12-600P

160 (Unit: mm)

Fig. 1-38 Fig. 1-42

THE CORRECT HANDLING OF POWER WRENCHES Misuse of power wrenches (part nos. 4093800 and 4229414) may lead to their breakage or personal injury. Please use power wrenches correctly and in accordance with this manual.

CAUTION 1. Changing the clutch · Set the base line of the dial to the R or L marker on the power wrench main body.

Clutch selection

(Select R for clockwise, L for counterclockwise movement.)

L (counter clockwise)

A tightening torque is applied with R and a loosening torque with L. Note that reverse

R (clockwise)

operation may damage the clutch. · The changeover clutch is intended to prevent reverse rotation when the force is released during a tightening or loosening operation, and is not designed to transmit torque in the manner of the ratchet handle.

Fig. 1-43

2. Stay away from the ratchet handle turning circle.

Fig. 1-44

3. Don' t drop the wrench. Excessive input torque may cause the output end or reaction lever to break, causing the wrench to become removed from the component. The wrench may also become removed if it slips off the reaction member. Secure the wrench so that it cannot fall, especially when working on vertical surfaces.

Fig. 1-45

Fig. 1-46

4. After tightening. It is sometimes difficult to remove the power wrench from a nut or bolt after tightening.This is generally due to elastic deformation (elastic force) between the wrench and bolt. Try changing the clutch direction to L to make the wrench easier to remove. Release the torque on the

ratchet handle gradually since a force will be acting in the opposite direction after changeover of the clutch. If it is not possible to change over the clutch by hand, do not attempt to use force (a hammer, etc.). · Try turning the wrench handle slightly in the L direction to make the clutch easier to change over.

Fig. 1-47 Fig. 1-48

(2548)

5. Power Wrench Input/Output Diagram Input/Output Diagram

(2254)

[Output=input x gear ratio x efficiency] (1960)

In selecting a power wrench, give due consideration of the differences in power performance between the different wrench types.

Output kgf·m (lbf·ft) (N.m)

(1666) (1372) (1078) (784) (490)

Bolt

Input kgf·m (lbf·ft) (N.m)

Power Wrench

(98)

(196) (294) (392) (490) (588) (686) (784) (882)

(6860)

(5880)

(4900)

Fig. 1-49

Output kgf·m (lbf·ft) (N.m)

(3920)

(2940)

(1960)

Input kgf·m (lbf·ft) (N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)

6. Torque Specifications

No.

Descriptions

Bolt Dia Wrench (mm) Side (mm)

Tightening Torque kgf·m

N·m

lbf·ft

Side frame mounting bolt

M36

285

2795

2060

Counterweight mounting bolt

M48

350

3430

2530

Counterweight lock plate securing bolt

690

510

ORS fittings for hydraulic hoses and piping

175

130

M24 3 1- 16 -12UNF 7 -12UNF 1- 16

205

150

M20

390

290

M20

390

290

M16

205

150

M12

Front pin retaining bolt (Backhoe)

Front pin retaining bolt (Loading shovel)

1-3 Work precautions

APPLYING LUBRICANT 1

Be sure to apply a suitable lubricant to mounting bolts before tightening. Use lubricant made by mixing white zinc jelly and spindle oil in 1: 1 proportions. In the case that these materials are not available, make up the lubricant from materials of the same composition: Material

Composition

White zinc jelly

Composition list given on page 26

Spindle oil

Composition list given on page 26

Lubricant should be applied to both the bolt and spacer, in the positions marked ＊ in the diagram below. Spacer

White zinc jelly Spindle oil

1:1

Lubricant

Bolt Fig. 1-50

＊ Face area

＊＊ Face area Thread

＊ Base of the head Fig. 1-51

HANDLING SEALS 1

High Tack Adhesive/ Sealant #98D

Remove the seal fitted to the ports and pipes of hydraulic components just before assembly, to prevent the ingress of dust. Oil will come out when removing the seals from the hydraulic ports. Collect it with a suitable oil container. Lightly apply High Tack Adhesive/Sealant #98D to the O-ring before hose connection.

Fig. 1-52

Note: Obtain high tack adhesive/sealant #98D through the manufacturer detailed on page 26. Fig. 1-53

CONNECTING HOSES. 1 2 3 4

Be careful not to damage the joining surfaces of the hydraulic components. Make sure that no dust has adhered to the seat faces of the hoses and adaptors. When connecting hoses, do not twist them or their service life will be shortened. When connecting the hoses, avoid contact with other parts.

Battery

CAUTION: Hydraulic ports are sealed with plugs on shipment from the factory. On removal of these plugs, hydraulic oil will escape due to the internal hydraulic pressure built up through transportation, etc.

POST-WIRING Be sure to remove the battery cables from the grounded (-) battery clamp before commencing electric wiring. This will help avoid short circuits during electric wiring work.

Fig. 1-54 Remove cables here

TIGHTENING LARGE-DIAMETER BOLTS DURING ASSEMBLY. 1

It is vital that large-diameter bolts be tightened to the specified tightening torque during assembly. If torque specifications are not followed, the operation of the machine will be affected, with machine failure, lowering of functionality and shortening of machine life potentially resulting. Be careful, therefore, to note the correct tightening torque at each stage of assembly. This manual describes use of a power wrench to achieve the required torque, but a hydraulic wrench will allow for even more accurate and efficient tightening work.

Fig. 1-55

Be sure to tighten each bolt to the specified torque using a torque wrench, power wrench, or hydraulic wrench. Torque wrench 1) After tightening a bolt to the specified torque, mark the alignment of the bolt head, spacer and bolted part. (See Fig. 1-55.) 2) Use only genuine Hitachi bolts.

Fig. 1-56

CAUTION: i) ii)

If a bolt is too long, you will not be able to fully tighten it. If a bolt is too short, you will not be able to be tighten it sufficiently to secure the parts, possibly resulting in a serious accident.

Pin Moly coat spray Fig. 1-57

NOTES ON INSERTING PINS WHEN AFFIXING THE FRONT-END ATTACHMENT. 1

When attaching the front-end attachment, thoroughly clean away the anticorrosive applied to the pins and pin holes before inserting the pins, then regrease them and spray them with Moly coat. Be sure to check the alignment of pin holes when joining parts. Do not use unreasonable force to insert pins, and attempt to insert all pins manually. If this is insufficient, use a medium-sized hammer to ease the pin in place. The use of forklift prongs to force in pins is absolutely forbidden. Any other unreasonable force can lead to a pin being misformed and rendered unusable, and should be avoided. (Fig. 1-58)

Fig. 1-58

APPLYING SEALING TAPE. Wrap sealing tape around the bolt in the opposite direction to the thread direction. Do not cover the first two threads, as indicated in Fig. 1-59.

Fig. 1-59

PRECAUTIONS FOR CONNECTING THE PILOT HOSES Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants may cause the pilot valve to malfunction.

Plug

Step 1

The ends of both the valve and hose to be connected will be sealed with plugs. Detail A

Fig. 1-60

Adaptor

Step 2

1) Remove the plugs. 2) Thoroughly clean the hose fitting and adaptor, then connect them, taking care to prevent the ingression of any contaminants.

Fitting Remove the plugs

Detail B Fig. 1-61

Step 3

Connect the adaptor and hose fitting.

Adaptor

Notes: When connecting hoses, do not twist them, or their service life will be shortened. ii) Connect the hoses so as to avoid contact with other parts. iii) Make sure that no dust has adhered to the seat face of the hoses. iv) Be careful to not damage the joining surfaces of the hoses.

Fitting

Detail C Fig. 1-62

Standards for Hydraulic Joint Work

ORS joint Work procedure 1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.

Note: Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!! Check for dirt and scars

Adapter

Hose, union part Fig. 1-63

O-ring

Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand 98D (Loctite, Ltd) to the screw part of the hose union.

Notes: i) Remember to handle the O-ring with your bare hands!! ii) Press the entire O-ring with your fingers and install it properly!! iii) Apply the bond uniformly to the groove. Do not overapply!! (Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.) Handle the O-ring with your bare hands!

Apply spray grease here.

Fig. 1-64

Screw the hose and union into the adapter.

Notes: i)

To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the hose horizontal to each other to keep them immobile!! ii) Tighten the union nut fully with your hands!! iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality, loosen the union nut and make sure to verify the O-ring!! Tighten the union nut fully with your hands

Fig. 1-65

Tightening the union â&#x20AC;˘ To tighten the union, use a spanner-style torque wrench and control the torque properly!! â&#x20AC;˘ Use a specified torque wrench!!

Note: After the work, carry out a check using a white pen!!

Union joint Work procedure 1 Check that the adapter and hose union seat surfaces are free of scars or dirt.

Note: Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!! Adapter seat surfaces

Hose union seat surface

Fig. 1-66

Fig. 1-67

Apply spray grease here 2

Apply spray grease to the screw parts of the hose and union.

Note: Do not overapply. (When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil leak.)

Screw the hose into the adapter.

Note: Tighten fully using your hands!! (If there are no scars on the thread, you will be able to screw it fully with your hands.) Tighten the union nut fully with your hands

Fig. 1-68

Tightening the union â&#x20AC;˘ To tighten the union, use a spanner-style torque wrench and control the torque properly!! â&#x20AC;˘ Use a specified torque wrench!!

Notes: i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it!! ii) After the work, carry out a check using a white pen!!

Split flange joint Work procedure 1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.

Notes: i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!! ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt!!

Check for scars and dirt

Fig. 1-69

O-ring 2

Hose, flange

Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D (Loctite, Ltd).

Notes: i) Remember to handle the O-ring with your bare hands!! ii) Apply the bond uniformly to the groove. Do not overapply!! (Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.) iii) Press the entire O-ring with your fingers and install it properly!!

Handle the O-ring with your bare hands. Do not overapply the bond. 3

Fig. 1-70

Installing the split flange 1) Temporarily install one side of the split flange using the socket bolts.

2) Confirm the O-ring and set the hose onto the split flange.

Note:

Notes:

Using your hands, screw in the bolt to about half its length!!

Make sure to insert the hose horizontally to the installation surface!! ii) Take care so that the O-ring does not fall out of place!!

Screw in the bolt to about half its length. Pay attention to the O-ring Fig. 1-71

Split flange

Socket bolts

Fig. 1-72

3) After setting the hose, install the other split flange.

Notes: i)

If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the Oring may fall off!! ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.

Install other split flange

Fig. 1-73

If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase, causing the O-ring to fall off

Fig. 1-74

Tightening the socket bolt 1) Temporary tightening, hose angle adjustment • Make sure to tighten the bolts in the correct order to avoid lopsided tightening. • The bolts should be tightened using a crisscross sequence. • The hose should still have movement even after the bolts have been tightened. • Adjust the hose angle.

2) Tightening the bolts • Tighten the bolts using a crisscross sequence in the same way as for temporary tightening. • Be careful not to tighten the bolts lopsidedly. • Be careful not to overtighten the bolts with an impact wrench. 3) Checking the torque

Bolt tightening sequence

• Use a torque wrench to check that the bolts are properly tightened. • Check the bolts in the same crisscross sequence as for tightening. • After the work, carry out a check using a white pen.

2 Fig. 1-75

No gap on one side and too much gap on the other side

In the case of lopsided tightening Fig. 1-76

Should be tightened so that the gaps are uniform Fig. 1-77

AFFIXING RUBBER BOOTS Note: DRC connector rubber boot handling precautions • Rubber boots should be fitted NIHON-DEUTSCH LIMITED-made DRC series connectors (24, 40, 70 poles), attached to excavator wiring joints to prevent water and dust from entering into the connector. • These rubber boots are supplied in a plastic bag together with the connectors during shipment, and should be stored similarly during disassembly. However, they may be lost, become removed or flinched during field assembly.

Rubber boots

• To prevent this problem, new connectors and rubber boots are designed to stick together so that they do not cone apart easily. • Securely attach the rubber boot to the male connector before assembly, then connect the male and female terminals. Take care that the rubber boot is not out of place or pinched during connection.

Rubber boots Fig. 1-78

ADJUSTING LIFTING ANGLE Example of usage of a chain block or lever block. By adjusting length â&#x20AC;&#x153;Lâ&#x20AC;? on the chain block (or lever block) connecting the wire ropes, the lifted angle of the load can easily be adjusted.

Wire rope

Chain block (Lever block) Chain block

Wire rope Lever block

Fig. 1-79

Work

Example The angle of the workpiece in Fig. 1-80 can be adjusted using chain blocks A .

Workpiece Chain block

Chain block

a<b

a=b

a Fig. 1-80

For reference 1

Ingredients of the white zinc jelly and spindle oil. White zinc jelly This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil. Ingredients: Extender pigment (calcium carbonate): 84.0% Color pigment (titanium oxide): 0.5% Fatty oil (polymerized oil): 14.0% Solvent (mineral turpentine): 1.5% Spindle oil Physical and chemical properties of this oil are as follows. (grade C machine oil) Appearance: Light brown Flash point (COC): Above 160째C (320째F) Density: 0.89 ~ 0.95 g/cm3 Fluid point: Below 10째C (50째F) Mixture: None Chemical name and composition: Petroleum system hydrocarbon 100%

Purchase high tack adhesive/sealant #98D from the following company: Company Name: Loctite, Ltd. Part Name: High Tack Adhesive/Sealant #98D Part No.: 80063 (Loctite Part No.)

Read the operation manual and this assembly procedure manual thoroughly to familiarize yourself with the work procedure.

Fig. 1-81

2. Work Plan and Preparations 2-1 Work Plan (Backhoe Front) The field assembly system facilitates easy machine assembly, without welding. Factors such as the workplace setting, working conditions, equipment and tool quality, and worker experience can lead to variation in the assembly schedule detailed below.

Days

day

Fine weather Crane (With operator and assistant)

30 t x 0.5 day

30 tonnes

2 sets x 0.5 day Scaffolding

Tool inspection

Unloading

Preparation

Unpacking major components

Workers

Part inspection

Supervisor 1 Workers 2 x 1 day

Cleaning parts

Assembly work

Frame assembly

Backhoe front assembly Counterweight assembly

Bucket assembly

Lubrication Track link adjustment

Adjustments

Operation

Touch-up painting Final assembly check

2-2 Work Plan (Loader Front) The field assembly system facilitates easy machine assembly, without welding. Factors such as the workplace setting, working conditions, equipment and tool quality, and worker experience can lead to variation in the assembly schedule detailed below.

Days

day

Fine weather Crane (With operator and assistant)

30 t x 0.5 day

30 tonnes

2 sets x 0.5 day Scaffolding

Tool inspection

Unloading

Preparation

Unpacking major components

Workers

Part inspection

Supervisor 1 Workers 2 x 1 day

Cleaning parts

Assembly work

Side frame assembly

Loader front assembly Counterweight assembly

Bucket assembly

Lubrication Track link adjustment

Adjustments Touch-up painting Final assembly check

Operation

TRANSPORTATION 2-3 Transportation

1. Unload the machine from the end of the trailer onto the ramp slowly.

Sub unit assembly part group The sub-unit assemblies are broken down into several components during transportation as listed below and therefore reconnection and reinstallation are required.

TRANSPORTATION CAUTION: In case the machine is equipped with a front attachment, be careful not to hit the boom with the bucket teeth when performing combined operation of arm roll-in/bucket roll-in or when rolling in the bucket wirh the arm fully retracted.

TRANSPORTATION

Transportation (Backhoe front)

E A

C G D

Example : Backhoe Front

(Unit: metric tonne) Base machine A 路 Boom B 路 Arm C 路 Bucket D 路 Boom cylinder E X2

Side frames F fitted

48-tonne trailer

Trailers/trucks

25-tonne trailer

18-tonne truck

15-tonne truck

10-tonne truck

Side frame F X 2

Counterweight G

Handrails, Ladders, Steps, etc. H

48t

25t

18t

15t

10t

Transportation (Loader front)

Example : Loader Front

(Unit: metric tonne) Base machine A · Boom linkage B · Bucket C · Boom cylinder DX 2

Side frames E fitted

48-tonne trailer

25-tonne trailer Trailers/trucks

20-tonne truck

15-tonne truck

10-tonne truck

Side frame E X 2

Counterweight F

Handrails, Ladders, Steps, etc. G

48t

25t

20t

15t

10t

NOTES

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

3. Parts check 3-1 Check

Unpack the major component parts.

Check their quantity against that shown on the packing list.

Check the parts for any damage during transportation. If there are any missing or damaged parts, take pictures of the damage and then contact Hitachi or your Hitachi distributor as soon as possible.

Fig. 3-1

4. Preparations 4-1 Preparations (Backhoe front) Work site: Select a flat, firm site. Work site size: 17 m Ă&#x2014; 20 m or larger. Crane: Prepare one 30 tonne crane. Arrange major components according to the diagram below. Arrange the parts according to the diagram below. 1 2 3 4 5 6 7 8 9 10 11 12 13

Base machine Boom (with arm cylinder) Arm (with bucket cylinder and link) Boom cylinder (L) Boom cylinder (R) Hydraulic hoses (for bucket cylinder) Hydraulic hoses (for boom cylinder) Counterweight Side step Handrails Oil tank steps Track frame steps Exhaust piping

14 15 16 17 18 19 20 21 22 23 24

Travel piping covers Track frame mounting bolts Wiper assemblyv Headlight Radio antennav Tool set Spare parts Key, O-rings, washers, part list, manual, etc. Backhoe bucket Side frame (L) Side frame (R)

18 17 21 7 6 20 19

14 13 12 16 15 11 10 9

22 2

5 4 1 3

20 m

m 17

4-2 Preparations (Loader front) Work site: Select a flat, firm site. Work site size: 17 m Ă&#x2014; 20 m or larger. Crane: Prepare one 30 tonne crane. Arrange major components according to the diagram below. Arrange the parts according to the diagram below. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Base machine Loader front assembly Boom cylinder (L) Boom cylinder (R) Hoses between boom and arm Hoses between arm and bucket Hoses between main frame and boom 2 pcs. Hoses between main frame and boom 2 pcs. Hose clamp between main frame and boom Hose clamp between boom and arm Boom cylinder hydraulic hoses Counterweight Side step Handrails Oil tank steps Track frame steps (for 650 mm shoes)

6 9

7 10 22

8 11 23

21 24

17 18 19 20 21 22 23 24 25 26 27 28

Exhaust piping Travel piping covers Track frame mounting bolts Wiper assembly Headlight Radio antenna Tool set Spare parts Key, O-rings, washers, part list, manual, etc. Loader bucket Side frame (L) Side frame (R)

18 17 21 16 20 15 19 14 13

2 3

1 28

20 m

m 17

5. Machines, apparatuses, tools, and materials necessary for assembly 1

Crane 30 tonne crane × 1

Wire ropes 34mmø (1.3 inø) 34mmø (1.3 inø) 26 mmø (1.0 inø) 26 mmø (1.0 inø) 26 mmø (1.0 inø) 24 mmø (0.9 inø) 18 mmø (0.7 inø) 18 mmø (0.7 inø) 14 mmø (0.55 inø) 14 mmø (0.55 inø) 12 mmø (0.45 inø) 10 mmø (0.4 inø)

× 10 000 mm (390 in L) × 3 000 mm (117 in L) × 10 000 mm (390 in L) × 8 000 mm (312 in L) × 3 000 mm (117 in L) × 10 000 mm (390 in L) × 10 000 mm (390 in L) × 3 000 mm (117 in L) × 10 000 mm (390 in L) × 3 000 mm (117 in L) × 5 000 mm (195 in L) × 3 000 mm (117 in L)

(L) × 2 (L) × 2 (L) × 2 (L) × 1 (L) × 2 (L) × 2 (L) × 4 (L) × 2 (L) × 5

Nylon sling belts 2 000 mm (L) × 2 (78 in) 4 000 mm (L) × 2 (156 in)

Shackles For 2.5 kg lond × 4

(L) × 1

5 000 mm (L) × 1 (197 in L)

100 mm (W) × (4.0 in) 20 mm (W) × (0.8 in) 5

(L) × 4

Guide rope 8 mmø × (0.3 inø)

(L) × 2

For 6 t load × 2

For 8 t load × 2

Chain blocks/lever blocks · Chain blocks

· Lever blocks

For 6 t load × 2 sets

For 1 t load × 2 sets For 2.5 t load × 2 sets

A description of chain/lever block use in keeping the load level is described in item 11 on page 25.

Wooden blocks 1 200 mm (L) × 800 mm (W) × 1 000 mm (H) × 4 (47 in) (31 in) (39 in) 100 mm (L) × 750 mm (W) × 50 mm (H) × 1 (4 in) (30 in) (2 in) 50 mm (L) × 50 mm (W) × 500 mm (H) × 4 (20 in) (20 in) (20 in) For 1 000 kg (2 200 lb) load × 2

Cylinder support Height:

1 800 mm (70 in) × 1

V-block V-block × 2 sets

Scaffolding 2 sets [Height about 3 000 mm (117 in)]

Oil containers 20 liter capacity × 4 10 liter capacity × 2

Standard tool kits Prepare 4 or more sets.

Touch-up paint Prepare 2 touch-up paint sets.

Pneumatic wrench (with compressor) 3 000 kgf·m (29 400 N·m/21 690 lbf·ft) capacity × 1 set

Hydraulic jack For 20 t load × 2

Protectors and patches Refer to Fig. 1 for an example protector. Protector × 5

Protector

Used tire

Hand tachometer or digital tachometer Pulsemeter, Adapter Engine speed sensor

Torque wrench

Fig. 1

60 kgf·m (600 N·m/435 lbf·ft) capacity 25 kgf·m (245 N·m/180 lbf·ft) capacity 20 kgf·m (195 N·m/145 lbf·ft) capacity 15 kgf·m (150 N·m/110 lbf·ft) capacity 10 kgf·m (100 N·m/075 lbf·ft) capacity 05 kgf·m (050 N·m/035 lbf·ft) capacity 02 kgf·m (020 N·m/015 lbf·ft) capacity 19

Safety belt × 4

Grinder

Halogen torch or charge detector For detecting refrigerant leaks.

Thermometer probe For measuring the refrigerant temperature. −10˚C to 100˚C × 1

Pressure gauge For measuring the pressure in the track link tension adjusting cylinder. 1960 Pa (200 kg/m2) capacity × 1

Miscellaneous Rags, cleaning agent, lubricant, light and cord reel, grease, Molycoat spray.

Tap (Refer to next page) M36 × P3.0

Lifting jig (Refer to next page) 1 set (2 pcs.)

Note: For the tools which are not available locally, place order to Hitachi in advance.

SPECIAL TOOLS Item

Illustration

Tool name

Q'ty

M36×P3.0 Tap

Usage

Tap to be screwed in bolt hole for tightening the side frame

Fig. 2

4093798 Torque wrench 10 ~ 42 kgf·m 100 ~ 410 N·m 75 ~ 305 lbf·ft capacity

Used to tighten the bolts.

4093800 Power wrench With wrench, socket P/No. 4298389

Used to tighten the side frame to track frame

4229414 Power wrench With wrench, socket P/No. 4298388

Used to tighten the side frame to track frame

Lifting jig (Right bracket) DWG. No. 8089397

Lifting jig of superstructure

Fig. 3

Max. output torque 450 kgf·m (4 410 N·m/3 255 lbf·ft)

Fig. 4

Fig. 5

Lifting jig (R)

Lifting jig (L)

Lifting jig (Left bracket) DWG. No. 8089392

Refer to appendix for a detailed description of the use lifting jigs

Fig. 6

Note: SPECIAL TOOLS (Others) Item

For tools which are not available locally, place an order with Hitachi in advance.

Illustration

Tool name

Q'ty

Usage

1 set

Used to create vacuum in the hydraulic tank

Vacuum pump Assembly ST6905 6

Vacuum pump Hose Nipple PT 1/8 Nipple PT 3/8 Fig. 7

ST6440 ST6326 ST6066 ST6068

NOTES

ASSEMBLY OF SUPERSTRUCTURE

SUPERSTRUCTURE

ZX800/ZX850H Assembly Manual

6. Assembly of superstructure 6-1 Preparation

Superstructure assembly flowchart

Fig. 1

Step 1

Parts required Item No. Shipping Part List

(00) (00) (00) (00)

Item No. Shipping Part List 02 03

04 05 06 06

07 08 08 09 09 12 10 14 11 15 12

(02) (03) (05) (04) (06) (03) (08) (09) (10) (11) (12) (14) (15) (

Part No.

Part name

Q'ty

Remarks

––– ––– ––– –––

ZX800 BASIC MACHINE ZX800 BASIC MACHINE ZX850H BASIC MACHINE ZX850H BASIC MACHINE

1 1 1 1

Superstracture + Track C/F Weight: 23 100 kg (50 820 lb) Superstracture + Track C/F + Track S/F Weight: 47 000 kg (103 400 lb) Superstracture + Track C/F Weight: 23 200 kg (51 040 lb) Superstracture + Track C/F + Track S/F Weight: 47 000 kg (103 400 lb)

Part No.

Part name

Q'ty

Remarks

––– ––– 6017693 6017693 6020843 6020843 8088866 7041515 8083266 7039946 7039947 ––– –––

SIDE FRAME (R) SIDE FRAME (L) STEP STEP STEP STEP HANDRAIL HANDRAIL HANDRAIL HANDRAIL HANDRAIL ANTENA ASS'Y MIRROR ASS'Y RIGHT

1 1 1 1 1 1 1 1 1 1 1 1 1

ZX800 ZX850H ZX800 ZX850H Right grab rail Battery cover above Fuel tank Oil tank Pump room Cab radio Right back mirror

) Shipping Part List No.

Item No. Shipping Part List 16 13

14 19 15

16 35 17 18 38 19 39 20 40 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 36 36 36

37 37 38 39 40 41 42 43

(16) (17) (19) (33) (35) (37) (38) (39) (40) (42) (51) (43) (52) (44) (53) (45) (50) (47) (47) (49) (55) (50) (56) (52) (78) (53) (79) (54) (80) (55) (81) (56) (82) (57) (83) (58) (84) (60) (58) (61) (59) (62) (60) (64) (62) (65) (63) (66) (64) (67) (66) (69) (42) (42)

Part No. ——— ——— 7040954 ——— 4391325 4218943 4218944 4242099 4242098 9212814 9212814 4504952 4504952 4061488 4061488 9159210 9159210 ——— 2045102 ——— ——— ——— ——— M923003 M923003 M923011 M923011 4114408 4114408 4218945 4218945 4243157 4243157 4207766 4207766 4333844 4333844 6019867 5008407 6019868 5008408 8082979 8082979 J222014 J222014 A590914 A590914 J901406 J901406 J021200 J021200 8069333 8069333 8068391

Part name MIRROR ASS’Y LEFT HORN PIPE; EXHAUST KEY OIL; HYD BOLT SPACER BOLT SPACER TOOL TOOL HANDLE; RATCHET HANDLE; RATCHET PIPE PIPE SPARE-PARTS SPARE-PARTS NAMEPLATE NAMEPLATE WIPER ASS’Y WIPER ASS’Y LIGHT ASS’Y LIGHT ASS’Y BOLT BOLT BOLT BOLT WASHER WASHER SPACER SPACER SPACER SPACER PLATE; LOCK PLATE; LOCK GUIDE GUIDE DUCT DUCT DUCT DUCT COVER COVER WASHER WASHER WASHER; SPRING WASHER; SPRING BOLT BOLT BOLT; SEMS BOLT; SEMS STEP STEP STEP

Q’ty 1 2 1 2 2 36 36 8 8 1 1 1 1 1 1 1 1 1 1 1 1 2 2 8 8 8 8 16 16 8 8 8 8 4 4 4 4 1 1 1 1 1 1 4 4 4 4 4 4 3 3 4 4 4

Remarks Left back mirror Exhaust pipe Replenishment Oil (HP46 (20 L): NISSEKI) Track S/F fix Track S/F fix Track S/F fix Track S/F fix ZX800 ZX850H ZX800 ZX850H Spare parts ZX800 ZX850H ZX800 ZX850H ZX800 ZX850H Blade + arm ZX800 Blade + arm ZX850H Upper cab light with bracket ZX800 Upper cab light with bracket ZX850H T/F Fixing bolt (ZX800) T/F Fixing bolt (ZX850H) T/F Fixing bolt (ZX800) T/F Fixing bolt (ZX850H) ZX800 ZX850H ZX800 ZX850H ZX800 ZX850H ZX800 ZX850H ZX800 ZX850H Duct rear with net (ZX800/ZX850H) EN Duct rear with net (ZX850H-EN) Duct front with net (ZX800/ZX850H) Duct front with net (ZX850H-EN) Duct visor (ZX800/ZX850H) Duct visor (ZX850H-EN) ZX800/ZX850H EN Duct rear with net (ZX850H-EN) ZX800/ZX850H EN Duct rear with net (ZX850H-EN) ZX800/ZX850H EN Duct rear with net (ZX850H-EN) ZX800/ZX850H EN Duct rear with net (ZX850H-EN) Track side step upper ZX800 Track side step upper ZX850H Track side step upper ZX800 (USA)

Spare parts

Item No. Shipping Part List

44 45 46 47 48 49 50 51 52 53

(70) (43) (71) (44) (73) (69) (74) (70) (75) (71) (76) (72) (77) (73) (78) (74) (79) (75) (80) (76) (＊＊) ( )

Part No. 8068378 8068378 J901650 J901650 6021470 6019840 6021479 6019841 7043553 7039800 7043554 7039801 8082865 8082865 8082866 8082860 8060558 8060558 8060559 8060559 8088575

Part name STEP STEP BOLT BOLT COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER; (R) COVER; (R) COVER; (L) COVER; (L) HANDRAIL

Q’ty 4 4 32 32 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks Track side step lower ZX800 Track side step lower ZX850H Track side step fix ZX800 Track side step fix ZX850H Travel piping cover (Right front) For ZX800 Travel piping cover (Right front) For ZX850H Travel piping cover (Left front) For ZX800 Travel piping cover (Left front) For ZX850H Travel piping cover (Right rear) For ZX800 Travel piping cover (Right rear) For ZX850H Travel piping cover (Left front) For ZX800 Travel piping cover (Left front) For ZX850H Travel piping cover (Right side) For ZX800 Travel piping cover (Right side) For ZX850H Travel piping cover (Left side) For ZX800 Travel piping cover (Left side) For ZX850H Fix bolt cover (Right) For ZX800 Fix bolt cover (Right) For ZX850H Fix bolt cover (Left) For ZX800 Fix bolt cover (Left) For ZX850H

No. on shipping part list Item No. Shipping Part List

Part No.

58 54 59 55 60 56 61 57 62 58

8088628 4282499 4464993 4465368 ———

(58) (59) (60) (61) (62)

Item No. Shipping Part List

Part No.

(00) (00) (01) (01) (02) (03) (03) (04) (04) (05) (05) (06) (07) (08) (09) (10) (10) (11) (12) (15) (16)

5007324 5008037 4345741 4345741 9701925 4335906 4103743 4345718 4246150 4405145 4341856 4346036 4221465 J912470 A590924 4335904 4114413 4380636 4380637 6019895 6019896

59 60 61

62 63 64 65 66 67 68

69 70 71 72 73

(

Part name BOX CLAMP; HOSE HOSE; AIR CLEANER; PRE BAND Part name COUNTER WEIGHT COUNTER WEIGHT SHIM SHIM PIN; RING WASHER WASHER NUT; U NUT; CASTLE BOLT BOLT SPACER STOPPER BOLT WASHER; SPRING WASHER WASHER SHIM SHIM HANDRAIL HANDRAIL

Q’ty

Remarks

1 2 1 1 1

For the ZX850H pre-cleaner ZX850H ZX850H ZX850H For fixing the ZX850H pre-cleaner and box; included in the band kit

Q’ty

Remarks

1 1 4 4 2 2 2 2 2 2 2 2 2 4 4 2 2 4 2 1 1

STD. Use when the counterweight removal/installation device is attached STD. Use when the counterweight removal/installation device is attached Use when the counterweight removal/installation device is attached STD. Use when the counterweight removal/installation device is attached STD. Use when the counterweight removal/installation device is attached STD. Use when the counterweight removal/installation device is attached

STD. Use when the counterweight removal/installation device is attached

) No. on shipping part list

6-2 Connecting the side frames to the track frame Step 1 Side frame (left) 03

Fitting the side frames

Cleaning the left side frame 03

Position side frame (L) 03 as indicated in Fig. 1. Use a tap to clean all bolt holes in each mounting face a and b of the side frame.

1 2

Tap size: M36 × P3.0 Clean the mounting faces of the side frame. Check each mounting face for damage or scratches.

Note: If the mounting face surface is damaged or scratched, repair or re-finish it.

Fig. 1

Detail A

Attaching wire ropes to the superstructure Attach wire ropes to superstructure 00 as indicated in Fig. 3.

Tap

Notes: i)

Use bolts to install lifting jigs on the counterweight mounting face. Refer to Appendix for a detailed description of the use of lifting jigs. ii) Install protectors to the left and right of the front of the main frame (2 locations), as depicted. Superstructure assembly weight: ZX800 23 100 kg (50 820 lb) ZX850H 23 200 kg (51 040 lb) Wire ropes

Fig. 2 Wire rope 34 mmø × 3 000 mm Chain block 6 ton Wire rope 34 mmø × 3 000 mm

2 pcs.

Protector:

2 pcs.

Shackle (for 6 tonne load):

2 pcs.

Wire rope 34 mmø × 10 000 mm

Shackle

34 mmø × 10 000 mm (L) : 2 pcs. (1.3 inø) (390 in L) 34 mmø × 3 000 mm (L) : 4 pcs. (1.3 inø) (117 in L)

Chain block (for 6 tonne load):

Lift

Bolt Protector

Lifting jig:

Lifting jig

1 set

Cleaning the track frame

Fig. 3 Hold

CAUTION: Position wooden blocks at the left and right of both the front and rear of the superstructure to prevent it from falling when cleaning its underside. Wooden block (for 6 tonne load): 4 pcs. Height: 1 000 mm (39 in) 1 2 3

Clean faces c ~ f of the track frame (4 locations - left/right of the front & rear). Thoroughly clean all bolt holes in the track frame. Check each mounting face surface for damage or scratches.

Note:

c d

Wooden block

If the mounting face surface is damaged or scratched, repair or re-finish it.

e f

Fig. 4

Hold

Preparing the side frames and superstructure for connection Hold superstructure 00 level.

Note:

Level the superstructure by adjusting the preset chain blocks.

CAUTION: Never allow anyone to stand directly beneath the lifted superstructure. Rotate the track frame. If the track frame is set to orientation A relative to the superstructure, start the engine and rotate the track frame by 90Â°, as indicated in Fig. 6 ( B ).

Track frame

Fig. 5

Notes: i)

In rotating the track frame, the superstructure must not be able to move after starting the engine. Before starting the engine, check the radiator and oil levels as described in the userâ&#x20AC;&#x2122;s manual. ii) Rotate the track frame slowly, and position subleaders at the front and rear of the superstructure to direct the procedure.

Hold

90Â°

B Fig. 6 Track frame

Slowly move the superstructure toward the left side frame 03 . 03

Superstructure track frame

Note: Make sure that the travel piping of the track frame faces toward the travel motor. Travel piping Side frame (L) assembly

Travel motor Fig. 7

Lift

Installing the left side frame (L) Move

Slowly move the superstructure toward the side frame. Align the bolt holes in the track frame and side frame. Apply lubricant to the screw and underside of the head of bolts 18 and 20 .

1 2 3

Side frame (L)

Notes: i)

Use lubricant made from white zinc and spindle oil mixed in 1:1 proportions. ii) Before installing the bolts 18 and 20 , apply lubricant to the screw and underside of the bolt head (＊ in Fig. 10).

Manually screw in bolts 18 fitted with spacers 19 18 sets.

Manually screw in bolts 20 fitted with spacers 21 4 sets.

Notes:

Travel piping

Fig. 8

Bolt

＊

Note that using excessive force in screwing in bolts can lead to damage to the thread. ii) Be careful not to mix up bolt-spacer combination ＊ Spacer types A and B (see Figs. 11 and 12). iii) Tighten each bolt until the mating faces make firm contact. iv) Check that the mating faces meet snugly. A

Fig. 10

Fig. 9

18 B

20 21

Detail B Bolt A

Bolt B

18 × 19 (8) 183

×4

Spacer

19 60

Fig. 11

233

× 19 (8)

Ratchet wrench

21 110

×4 Fig. 12

Tighten bolts 18 and 20 fitted in steps 4 and 5 above, with a ratchet wrench.

Fig. 13

Tighten the bolts with a power wrench to the specified torque.

Tightening torque: Bolts A , B 285 kgf·m (2 795 N·m/2 060 lbf·ft)

power wrench

CAUTION: Be careful that your hands are not caught by the reaction force acting on the bar of the power wrench.

Fig. 14

8 9 10

Fit guides 35 using bolts 30 , washers 31 and spacers 33 . Fit lock plates 34 using bolts 29 , washers 31 and spacers 32 . Tighten the bolts to the specified torque using a power wrench.

31 34

30 31 35

Tightening torque:

285 kgf·m (2 795 N·m/2 060 lbf·ft) 33

CAUTION: Fig. 15

Be careful that your hands are not caught by the reaction force acting on the bar of the power wrench.

Detail C 29

×4

159

×2

34 32

×2

×4 ×4

Fig. 16

After connecting the superstructure and left side frame, place 2 wooden blocks under the right side of the track frame and lower the track frame onto the blocks such that the right frame side is lifted about 150mm (6 in) to 200mm (8 in) above horizontal.

Wooden blocks:

Lower

2 pcs. Track frame

Note: The wooden blocks must each be able to support a load of at least 10 tonnes.

CAUTION: Lowering the track frame onto blocks makes the subsequent work safer than keeping the superstructure suspended with a crane.

Remove the wire ropes and lifting jigs attached to the superstructure.

150 ~ 200mm (6 ~ 8 in) Wooden block (× 2) Fig. 17

Remove

Lifting jig

Fig. 18

15 Step 2 Installing exhaust pipe 15

Note: Assemble the exhaust pipe of the muffler. Position the pipe at the rear of the machine. Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft) Fig. 19

Step 3 Installing the right side frame (Right)

Preparing the superstructure 1

Swing 180°

Start the engine and slowly rotate the superstructure 180°.

Note: Rotate the track frame slowly, and position subleaders at the front and rear of the superstructure to direct the procedure. 2

Clean the mating faces of the track frame (2 positions a ).

a Clean Fig. 20

02 Side frame (Right)

Cleaning the right side frame 02 1

Use a tap to clean all bolt holes in each mounting face b and c of side frame 02 .

b c

Tap size: M36 × P3.0 2

Clean the mounting faces of the side frame. Check each mounting face for damage or scratches.

Note: If the mounting face surface is damaged or scratched, repair or re-finish it.

Fig. 21

Detail D

Tap

Fig. 22

Hold

Attaching wire ropes to the right side frame Attach wire ropes to right side frame 02 as indicated in Fig. 23.

Wire rope 26 mmø × 8 000 mm

Note: Install protectors to the 4 locations on the track indicated in Fig. 23.

Side frame assembly weight: ZX800 (650 mm shoes): 11 600 kg (25 520 lb) ZX800 (750 mm shoes): 11 950 kg (26 290 lb) ZX850H (650 mm shoes): 11 700 kg (25 740 lb) Wire ropes: 26 mmø × (1.0 inø)

8 000 mm (L) : 2 pcs. (312 in)

Protectors:

Protector

＊ About 1 800 mm

4 pcs. Travel motor

Fig. 23

Lift the side frame.

CAUTION: Make sure that no-one enters underneath the lifted side frame.

Notes: In lifting the side frame, keep the distance ＊ between the points of contact of the wire rope loops, as small as possible. This is to prevent the wire ropes contacting the cab or track frame. ii) Note that the travel motor is heavy. Be careful to align the wire rope loops appropriately around the center of gravity of the side frame, such that the side frame is longitudinally level when lifted. iii) Follow the procedure given below to tilt the side frame slightly, such that the mating faces of the side frame and track frame are aligned.

Detail E Raise

Attach wire ropes to the side frame.

Inside

Lower

Raise vertically.

Outside

Raise

Position a wooden block underneath the outside edge of the side frame and momentarily lower the side frame onto the block. (2 pcs.) Wooden block

On relifting the side frame, it should be tilted as depicted.

Connection with the superstructure can be carried out smoothly with the side frame in this state.

Fig. 24

Wooden block: 2 pcs. for 1 000 kg (2 200 lb) load

Raise

Installing the right side frame

Move

Move the lifted right side frame toward the track frame. Move the side frame horizontally in the direction of the arrow, and align the bolt holes in the track frame and side frame.

Side frame (R)

Apply lubricant to the screw and underside of the head of bolts 18 and 20 .

Fig. 25

Notes:

Hold

Use lubricant made from white zinc and spindle oil mixed in 1:1 proportions. ii) Before installing the bolts 18 and 20 , apply lubricant to the screw and underside of the bolt head (＊ in Fig. 29).

Manually screw in bolts 18 fitted with spacers 19 18 sets.

Manually screw in bolts 20 fitted with spacers 21 4 sets.

Fig. 26

Detail F

Notes: i)

Note that using excessive force in screwing in bolts can lead to damage to the thread. ii) Be careful not to mix up bolt-spacer combination types A and B (see Fig. 28). iii) Tighten each bolt until the mating faces make firm contact. iv) Check that the mating faces meet snugly. 5

Torque wrench

Tighten bolts 18 and 20 fitted in steps 3 and 4 above, with a ratchet wrench. Fig. 27

Detail G Bolt A

Detail H Bolt

＊

Bolt B

× 18

×4 183

233 Chamfering

Spacer

Spacer 21

＊ ×4 Section

110 Spacer

× 18 Fig. 28

Fig. 29

Tighten the bolts with a power wrench to the specified torque.

Tightening torque:

Detail I

285 kgf·m (2 795 N·m/2 060 lbf·ft)

Power wrench

CAUTION: Be careful that your hands are not caught by the reaction force acting on the bar of the power wrench.

Fig. 30

7 8 9

Fit guides 35 using bolts 30 , washers 31 and spacers 33 . Fit lock plates 34 using bolts 29 , washers 31 and spacers 32 . Tighten the bolts to the specified torque using a power wrench

30 31 35

31 34 32

Tightening torque:

285 kgf·m (2 795 N·m/2 060 lbf·ft)

CAUTION: Be careful that your hands are not caught by the reaction force acting on the bar of the power wrench. Fig. 31

Detail J 29

30 ×4 129

×4

159

×2

34 32 33 ×4 40

×2 ×4

Fig. 32

Step 4 Hold

Removing the wooden blocks

Removing the wooden blocks 1

Slightly lift the right side frame such that it is suspended above the ground. Place a wooden block and jack underneath both the front and rear of the track frame as depicted at right, and jack the track frame up off the supporting wooden blocks. Jack

Wooden block

Fig. 33

wooden blocks Hold

Remove the wooden blocks, and lower the side frame such that it rests on the ground.

Remove the wooden blocks

Fig. 34

Remove the wire ropes from the side frame.

Remove wire ropes

Fig. 35

Changing the orientation of the superstructure

Rotate the superstructure 90Ë&#x161;

Start the engine and rotate the superstructure 90Â° such that the cab faces forward.

Note: Rotate the track frame slowly, and position subleaders at the front and rear of the superstructure to direct the procedure. Fig. 36

Step 5 Connecting the travel motor hoses

Removing the travel motor covers Remove travel motor cover a . Remove the travel motor cover for the opposite side frame.

1 2

Installing the travel hoses

Note: Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure. Remove the caps from the travel motor ports and travel hoses.

CAUTION:

Fig. 37

In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. Connect travel hoses b , c , d and e to the travel motor. Number tags are provided on each port and hose. Connect the hoses, matching the numbers.

Tightening torque: b , c : d

11 kgf·m (110 N·m/80 lbf·ft) 18 kgf·m (175 N·m/130 lbf·ft) 9.5 kgf·m (95 N·m/70 lbf·ft)

Connect the travel hoses for the opposite travel motor in the same manner.

Notes: i) ii) iii) iv) v)

Connect the hose so it does not make contact with other parts. Make sure that no dust has adhered to the seat face of the hose. Do not damage the joining surfaces of the hose. Do not twist hoses when connecting them. Their service life will be shortened. Use O-rings to connect the hoses. Apply a thin layer of sealant #98D to the O-ring before installation.

Detail K

After connecting the travel motor hoseing, clean away any residue oil from the outside of all parts.

Detail L

Fig. 38

b c

d e

Fig. 39

Reinstalling the travel motor piping covers Reinstall travel motor cover a removed in step-5 1 above. Install travel motor piping covers 46 , 48 , 50 and 52 . Install travel motor cover a and travel motor piping covers 47 , 49 , 51 and 53 for the opposite travel motor, in the same manner.

1 2 3

Tightening torque:

21 kgfÂˇm (205 NÂˇm/150 lbfÂˇft)

Notes: Fig. 40

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

50 52

46 48 Fig. 41

Fig. 42

Step 6 Installing the steps and handrails

Install steps 43 and 44 to the side frame using bolts 45 , washer, spring washer. Tightening torque: 21 kgf·m (205 N·m/150 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque. iii) Install the steps for the opposite side frame in the same manner.

43 44

Fig. 43

Install steps 04 and 05 to the superstructure. Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

04 Fig. 44

05 09 10

Install handrails 09 and 10 to the oil tank.

Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque. Fig. 45

Install handrails 07 and 08 to the fuel tank.

Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Fig. 46

Step 7

FOR ZX800

Accessory installation

28 27 13

Use bolts to install side mirror assemblies 12 and 13 to their respective stay/clamp, as illustrated in Figs. 47 and 48. Tightening torque:

Antenna 11

Handrail a

Install the side mirrors

1 kgf·m (10 N·m/7.2 lbf·ft)

Install the windscreen wiper 1

Install windscreen wiper assembly 27 as illustrated in Figs. 47 and 48.

Connect electric wire coupler.

＊＊

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

Install the head lamps Fig. 47

Install head lamp assemblies 28 as illustrated in Fig. 47.

Tightening torque:

FOR ZX850H

9 kgf·m (95 N·m/65 lbf·ft)

The head lamps are built into the head guard for ZX850H machines

Antenna 11

Handrail a

27 13

Connect electric wire coupler.

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

Note:

＊＊

This procedure is not necessary for ZX850H machines, as the head lamps are built into the head guard. (See Fig. 48).

Install handrail to the side of the superstructure as illustrated in Figs. 47 and 48. (When installing the 900G shoe) Tightening torque:

9 kgf·m (95 N·m/65 lbf·ft)

Fig. 48

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Install handrail 06 to the side of the superstructure as illustrated in Figs. 47 and 48. Tightening torque:

9 kgf·m (95 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Installing the antenna 1 2

Install antenna 11 as illustrated in Figs. 47 and 48. Connect electric wire coupler.

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

In order to facilitate the easy installation of the boom foot pins, temporarily remove handrail a , attached to the superstructure. (This handrail is reinstalled at the completion of boom installation.) See Figs. 47 and 48.

Note: Be careful not to damage the rearview mirror 12 attached to the handrail, during removal.

Accessory installation (Pre-cleaner and horn)

Detail M

Install the pre-cleaner

a Fig. 49

Cap a is attached to the air intake port in the air cleaner to prevent the entry of rainwater. Remove cap a this should be scrapped. Install pre-cleaner 57 , band 58 , box 54 , air hose 56 , and hose clamps 55 , as shown in Fig. 51.

Tightening torque:

6 kgf·m (60 N·m/43 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Fig. 50

Detail N

57 58 54 55

Install the horns

55 Fig. 51

Install horns 14 on the front side of main frame.

Note: Install the blue horn (Hi) on the right side and the red horn (Lo) on the left side by facing the forward direction. Take care so that they are correctly positioned. Tightening torque:

3 kgf·m (30 N·m/20 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Fig. 52

Detail O 14

14 Hi (blue)

Connect the electric wire couplers for the horns. Lo (red)

Note:

Fig. 53

Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

Fig. 54

Accessory installation (Ducts, cover and caution plate)

Detail P

Install ducts 36 , 37 , and cover 38 . Ducts 36 and 37 conform with the EN specification.

Note:

Use washer 39 , spring washer 40 , bolt 41 , and sems bolt 42 to install the ducts and covers. Tightening torque M10: 5 kgf·m (50 N·m/36 lbf·ft) Tightening torque M12: 9 kgf·m (90 N·m/65 lbf·ft) Tightening torque M14: 14 kgf·m (140 N·m/100 lbf·ft) Tightening torque M16: 21 kgf·m (205 N·m/150 lbf·ft)

Notes: Fig. 55

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque. iii) Machines with serial no. 6196 and up have onepiece 36 , 37 , and 38 . However, those for EN remain unchanged as shown here.

Preparation of nameplate 26 Nameplate 26 contained in the box together with the parts shipped is a caution plate. This caution plate is to be used by hanging on either the door handle or engine key cylinder when necessary. It is desirable that the caution plate should always be used during assembly and repair work.

Fig. 56

Detail Q Detail R

Fig. 57

Fig. 58

6-3 Mounting the counterweight Step 1 Mounting the counterweight

Remove covers a and b from underneath the superstructure before installing the counterweight.

Cover b Fig. 1

Cover a

Attaching wire ropes to the counterweight 1

Lift

Attach wire ropes to counterweight 59 as indicated in Fig. 2.

Counterweight:

12 500 kg (27 000 lb)

Wire ropes: 2 pcs. 24 mmø (0.9 inø)

Wire rope 24 mmø× 10 000 mm

10 000 mm (L) (390 in L) Shackle

Shackle (for 8 tonne load): 2

2 pcs.

Adjust the wire rope to make the counterweight level.

Counterweight 59

CAUTION: Never allow anybody to stand directly beneath the lifted counterweight.

Fig. 2

Lift

Installing the counterweight 1

Move

Slowly move the counterweight towards the main frame, such that the projection on the counterweight connecting face mates with the mounting holes in the main frame.

60 59

CAUTION: Never allow anyone to enter into the area under the lifted counterweight. 2

63 Apply lubricant to the base of the bolt head ďź&#x160;

Install counterweight mounting bolts 64 and spacers 65 (external diameter 80 mm). Temporarily install shims 60 , washers 62 (external diameter 90 mm) and castle nuts 63 on bolts 64 from the main frame side.

ďź&#x160; Apply lubricant to the thread

Fig. 3

Notes: i)

Before installing the bolts 64 , apply lubricant to the screw and underside of the bolt head (ďź&#x160; in Fig. 3). Use lubricant made from white zinc and spindle oil mixed in 1:1 proportions. ii) Tighten each bolt until the mating faces make firm contact. iii) Check that the mating faces meet snugly.

Note: Shims 60 must be installed in the orientation depicted in Fig. 4. Make sure that the shims are installed in such a way as to keep the nuts from loosening.

Detail A 65

Fig. 4 Hold

Fig. 5

Securing the counterweight in place 1

Detail B

Tighten counterweight mounting bolts 64 such that the counterweight is flush against the main frame. Install washers 69 , anti-rotational stoppers 66 and spring washers 68 on the mated counterweight projections, and secure them in place with bolts 67 . Use shims 70 and 71 (t=1.0 and 2.0, respectively) to remove any gap between stoppers 66 and washer 69 . Check that the counterweight is flush against the main frame. Tighten counterweight mounting bolts 64 .

Fig. 6 Hold

IMPORTANT: The counterweight is mounted with two bolts. Check the width across flats of nut or castle nut 63 first and tighten bolt 64 to torque specified below: Width Across flats of nut or castle nut 63 70 mm (with counterweight removal/installation device) 75 mm (STD.)

70 71

66 64

Note: After tightening the bolt to the specified torque, secure castle nut 63 with ring pin 61 if the counterweight is provided with the counterweight removal/installation device. Counterweight mounting bolt tightening torque: Nut wrench size: 70 mm 280 kgf·m (2 745 N·m/2 025 lbf·ft) Nut wrench size: 75 mm 350 kgf·m (3 430 N·m/2 530 lbf·ft)

67 68 Fig. 7

Detail C

Note: Tighten the bolts with a power wrench. 66

CAUTION: Be careful that your hands are not caught by the reaction force acting on the bar of the power wrench. 4

68 67 69 70 71

Tighten the bolts fixed to the counterweight projection.

Locking plate tightening torque:

70 kgf·m 690 N·m/510 lbf·ft

Fig. 8

Remove the wire ropes

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque.

Finishing up 1 2

Remove the wire ropes and shackles attached to the counterweight. Reinstall covers a and b removed in 1 .

Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft) a

Fig. 9

Install, handrails 72 and 73 on the counterweight.

Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the thread of the mounting bolts before installation. ii) Hand screw in all bolts first, before tightening to the specified torque. Fig. 10

Fig. 11

Step 2 Touch-up painting and final check

Touch-up painting After completing the above steps and installing the handrails, touch-up the paintwork.

Fig. 12

Detail D

Final checks of the superstructure Check that all the bolts on the superstructure have been tightened to the prescribed torque.

Fig. 13

6-4 Greasing of swing bearing Greasing (1)

Detail A a

The machine is provided with a pneumatically operated grease lubricator connected to the hose reel and a grease gun. Operation procedure: (1) Connect air supply hose to lubricator pump a . (2) Pull out the grease hose from hose reel c while holding grease gun b . (3) Stop pulling out when the reel clicks and desired hose length is obtained; the hose will be locked automatically. (4) Connect grease gun b to the desired grease fitting and pull the gun lever; grease will be supplied automatically by air pressure.

IMPORTANT: Run the engine at medium speed or more when supplying grease using the lubricator.

Start the engine.

Supply grease to 3 points as shown in Fig. 3.

Fig. 1

Notes: i)

When using a lubricator, increase the engine speed above medium speed. ii) If an optional automatic greasing system is not equipped, the ZX800/ZX850H comes equipped with a standard air grease gun. Grease up at the front pins with the air grease gun manually. iii) Insufficient greasing will cause wear to the pins.

Fig. 2

Detail B

Swing bearing

Fig. 3

Lubrication method (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

d e

IMPORTANT: When the pump begins to suck grease, any air inside pump a will be mixed in, making grease turn whitish. Open check valve cock e to bleed this air-mixed grease. Securely close check valve cock e when all air-mixed grease is bled out.

(2) Grab high-pressure grease gun b and pay out the hose from hose reel c to the length required.

Fig. 4

(3) Press hydro-chuck g protruding from highpressure grease gun b into a grease nipple and pull the lever to discharge grease. (4) Release the lever when greasing is complete; grease discharge will stop.

IMPORTANT: When detaching hydro-chuck g from grease nipple h , grease nipple h tip may break unless a special care, is taken, as follows: Âˇ Tip nozzle f a little so as to release the connecting pressure applied to hydro-chuck g . Âˇ Slowly detach hydro-chuck g from nipple h .

g f b

(5) When all greasing work is complete, turn power switch d OFF, then pull grease gun b lever to release remaining pressure from grease gun b , pump a , and the hose so as to ensure long life of the components. A little grease will be discharged at this time.

c Fig. 5

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.

h Fig. 6

6-5 Final check of superstructure

Detail A a

Step 1 Checking the levels

Note: The person in charge of assembly must confirm the check items in this step. Incorrect operation will damage the equipment.

Check the coolant levels a in the radiator (See Figs. 1 and 2). If the level is low, refill through the filler ports b on the radiator. Refer to the OPERATION MANUAL for details.

Fig. 1

Detail B

IMPORTANT: Do not remove the radiator cap while the coolant is still hot, as high temperature coolant may gush out of the radiator causing injury. Instead, gradually loosen caps b once the coolant temperature has dropped. Check that the coolant level is between the HIGH and LOW marks on the level gauge. Remove the radiator cap and add coolant if the level is low.

Fig. 2

Detail C

Check the oil levels c in all reduction gears for swing reduction devices. Refer to the OPERATION MANUAL for details.

CAUTION: The machine will be hot immediately after operation. Allow the machine to cool adequately before checking the oil levels.

Check the oil level d in the engine oil pan. Refer to the OPERATION MANUAL for details.

Fig. 3

Detail D d

CAUTION: The machine will be hot immediately after operation. Allow the machine to cool adequately before checking the oil levels.

Check the oil levels e in the final drives. (both sides) Refer to the OPERATION MANUAL for details.

Fig. 4

Detail E

IMPORTANT: Never stand in front of the final drives when doing this work. Loosen the plug by 2 to 3 turns to allow any residual pressure in the travel device to escape, before fully removing the plug. If the plug is removed without letting residual pressure escape, the plug and gear oil may gush from the machine, causing injury. Do not stand or place your face directly in front of the plug.

Fig. 5

Detail F

Check the fuel level in the fuel tank. Refer to the OPERATION MANUAL for details.

CAUTION: Handle fuel carefully. Shut the engine off before fueling. Do not smoke while you fill the fuel tank or work on the fuel system. Check fuel level indicator a or fuel level gauge c on the monitor panel. Add fuel via fill cap b if necessary. The fuel capacity is approximately 900 liters (238 US gal).

Detail H

Fig. 6

Detail G

Fig. 8

Fig. 7

Detail I Fuel level gauge c

Fig. 9

Fig. 10

Detail J

Check the pump transmission oil level. Refer to the OPERATION MANUAL for details. 1 2

Remove dipstick d . Oil must be between the marks. If necessary, add oil after returning the dipstick to its original position.

CAUTION: The machine will be hot immediately after operation. Allow the machine to cool adequately before checking the oil levels.

Fig. 11

Detail K

Note: The person in charge of assembly must confirm the check items in this step. Incorrect operation will damage the equipment.

Checking the hydraulic oil level. Refer to the OPERATION MANUAL for details. Check that the level of oil in the hydraulic tank is above the range indicated in the oil level gauge a .

Fig. 12

Detail L

Note: Release the air from the main pump at the same time as you add hydraulic oil. (See page 87 for details of the air release procedure.)

Fig. 13

Step 2 Checking the battery 1

Connecting the battery cables to the batteries. Before connecting the battery cables, clean of the anticorrosive and rust from the connections. Checking the liquid level of battery and specific gravity.

Fig. 14

Detail M

Connecting the battery cable

Fig. 15

6-6 Releasing the air from the main pumps IMPORTANT: If the hydraulic pump is not filled with oil, it will be damaged when the engine is started. The machine is equipped with two main pumps. Bleed air from these pumps after changing hydraulic oil.

1 2 3

6 7

Remove plug a from the top of each pump side to release trapped air. Fill the pumps with oil and temporarily tighten the plug a . Start the engine and run at slow idle. Put a "Do Not Operate" tag on the pilot control shut-off lever. Make sue the pilot control shut-off lever is in the LOCK position. Slowly loosen the plug a to release trapped air. Retighten the plug a when air stops and oil flows from the hose ends. Purge air from the hydraulic system by running the engine at slow idle and operating all control levers slowly and smoothly for 15 minutes. Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended. Lower the bucket to the ground.

Fig. 1

Detail A a

Note: Follow steps 6 and 7 above only when the front attachment is installed. 8 9 10 11

Turn the auto-idle switch off. Stop the engine. Remove the key from the key switch. Pull the pilot control shut-off lever to the LOCK position. Check the hydraulic oil tank gauge. Add oil if necessary.

Fig. 2

Retighten dust sensor plug securely. Tightening torque:

16 to 18 kgf·m 157 to 176 N·m 115 to 130 lbf·ft

CAUTION! This operation must be done slowly. Avoid abrupt operation!

Confirm hydraulic oil level in the hydraulic tank. Add hydraulic oil if required.

After the oil has flowed out clean the parts carefully.

6-7 Trial operation of superstructure

Trial operation

1 2 3

Start the engine. Refer to the OPERATION MANUAL for details. Check the operation of the gauges. Check the travel and swing functions. Swing

CAUTION: This operation must be done slowly. Avoid abrupt operation! 4 5

Check for oil leakage. Confirm that there is no oil leaking from the assembled areas. Check the amount of oil in the hydraulic tank. If the oil level is low, add oil through the oil filler port on the hydraulic tank. Fig. 1

CAUTION: Make sure nobody other than the operator is in or on the hydraulic excavator before starting the operation.

Traveling

Fig. 2

Confirm that machine noise is maintained at specified levels.

Detail A

Fig. 4

Fig. 3

NOTES

ZX800/ZX850H Assembly Manual

BACKHOE FRONT

ATTACHMENTS

MOUNTING PROCEDURE FOR FRONT-END ATTACHMENTS

7. Backhoe front mounting procedure 7-1 Preparation

Backhoe front assembly flowchart

Fig. 1

Step 1

Parts required Item No. Shipping Part List

Part No.

00 01 02 03 04 05 06 07

4331075 4331076 4089703 M341445 4450978 4414282 4508805 4187328

(22) (23) (25) (26) (28) (29) (30) (31) (

Part name CYL., BOOM (R) CYL., BOOM (L) FLANGE; SPLIT BOLT; SOCKET HOSE HOSE O-RING O-RING

Qâ&#x20AC;&#x2122;ty 1 1 8 16 2 2 6 2

Remarks

Boom cyl. Boom cyl. rod Boom cyl. bottom Boom cyl. bottom + rod Boom cyl. rod

) No. on Shipping part list

Item No. Shipping Part List

08 09 10 11 12 13

14 15 16 17

(00) (00) (02) (02) (04) (04) (06) (06) (07) (07) (08) (10) (10) (＊＊) (＊＊) (13) (11) (15) (16) (

Part No. ——— ——— ——— ——— ——— ——— 4373644 4364317 4508805 4508805 4510169 4379158 4386485 4487585 4487581 4379157 4386486 ——— ———

Part name BOOM BE BOOM ARM BE ARM BUCKET BUCKET (4.3 m3 ROCK) HOSE HOSE O-RING O-RING O-RING PLATE, THRUST PLATE, THRUST O-RING O-RING PLATE, THRUST PLATE, THRUST LAIT ASSEMBLY LAIT ASSEMBLY

) No. on Shipping part list

Q’ty 1 1 1 1 1 1 2 2 6 5 3 2 2 4 4 2 2 2 2

Remarks With arm cylinder (STD/HD) With arm cylinder (BE) With bucket cylinder (STD/HD) With bucket cylinder (BE) (STD/HD) (BE) (STD/HD) (BE) (STD/HD) (BE) (STD/HD/BE) (STD/HD) (BE) (STD/HD) (BE) (STD/HD) (BE) (STD/HD) (BE)

7-2 Mounting the backhoe front Step 1 Note: Do not completely detach the pin

Preparing the base machine

Preparing the base machine Remove the boom foot pin fitted to the base machine.

Notes: i)

Do not completely remove the pin, but leave the pin end attached to the inside of the right-hand bracket. ii) Shims are attached to the foot pin, which are to be used during pin installation and should be stored safely until such time. 2 3

Fig. 1

Clean away the anti-corrosive applied to the boom foot pins and pin holes. Apply grease to the boom foot pin and pin holes.

Lift

Step 2 Installing the boom cylinders

Attaching wire ropes to the boom cylinders 1

Attach wire ropes to boom cylinder (L) 01 as indicated in Fig. 2.

Boom cylinder weight: Wire ropes: 12 mmø × (0.45 inø)

700 kg (1 540 lb)

5 000 mm (L) : (195 in L)

2 pcs.

Clean away the anti-corrosive applied to bottom and rod boss a and b of the boom cylinder. Apply grease to boss a and b .

1 2

Lifting boom cylinder 01 Lift the boom cylinder, keeping it level.

Wire rope 12 mm ø × 5 000 mm

01 a

Fig. 2

Note: The left and right boom cylinders differ in the manner depicted in Fig. 3. Be sure not to mix them up.

00 Right boom cylinder Hydraulic piping

01 Left boom cylinder

Fig. 3

Preparing the boom cylinder foot pins for installation Remove boom fit pins a and b fitted to the base machine.

Notes: i)

Do not completely remove the pins, but leave the pin end attached to the inside of the insidefacing bracket. ii) Shims are attached to foot pins a and b which are to be used during pin installation. 2 3

a b

Clean away the anti-corrosive applied to the boom foot pins and pin holes. Apply grease to the boom foot pins and pin holes.

Fig. 4 Hold

Move

Installing boom cylinder (L) 01 1

Move the boom cylinder toward the base machine, such that the bottom boss of the boom cylinder aligns with the frame boss.

Bolt Spring washer Plate

Note: Install the boom cylinder such that the hydraulic piping faces downward. 01 2 3

4 5

Align the pin holes of the boom cylinder and base machine. Check the size of clearance c . If c is more than 4mm, fit the shim attached to the pin, on the side away from the pin head. Insert pin b , being careful not to damage the seal on the cylinder. Fit and tighten the plate with bolts and spring washers.

Install the boom cylinder with the hydraulic piping facing downward. Fig. 5

Detail A Shim

Pin b

Plate

Note:

Clearance

Apply lubricant to the pin before installation. Bolt, spring washer

Cab side Fig. 6

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Lower the boom cylinder onto a cylinder support such that it is maintained level. Install boom cylinder 00 in the same manner as described above.

Note: Place a V-block shaped rest under the top of the boom cylinders to protect the hydraulic piping. Cylinder support: 1 pc. Height: 1 800 mm (70 in) V-block:

01 V-block

Boom cylinder support

2 pcs. Fig. 7

Step 3

Boom cylinder hoses 05 (Out side)

Connecting the boom cylinder hoses

Connecting the boom cylinder hoses Boom cylinder 04 rod hose (In side)

Note: Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure. Remove the caps from the ends of the hoses.

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. Connect the boom cylinder hoses 04 and 05 between the boom cylinders and base machine. Use split flange 02 and socket bolts 03 during this work.

Fig. 8

Tightening torque: 14 kgf·m (140 N·m/100 lbf·ft)

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to make contact with other parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 06 (P/No. 4508805) and 07 (P/No. 4187328) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

After connecting the hoses, clean away any residue oil from the outside of all parts.

Step 4 Bleeding the boom cylinders

Bleeding the boom cylinders Start the engine and set it to run at low idle. Slowly extend the boom cylinders to bleed any air trapped inside, repeating the process until the cylinder rods extend at constant speed.

Boom cylinder

Notes: i)

Avoid operating the cylinders jerkily, rapidly or in any other way which could damage the cylinder seals. ii) For the first 4 repetitions, stop the cylinders 100mm before the rod stroke end. iii) Move the cylinders to full stroke on the 5th repetition. iv) Hold the cylinders at stroke end for 1 minute to allow all air to escape under relief pressure.

Fig. 9

After completely bleeding the boom cylinders of air, retract them in preparedness for the next step.

Step 5

08 Wooden block

Reparation of the boom

Arm cylinder

Place wooden blocks under boom 08 as shown in Fig. 10. Boom 08 weight: STD 8 500 mm H 8 620 mm BE 7 500 mm Long 10 310 mm

7 090 kg 7 610 kg 7 200 kg 8 020 kg

(15 600 lb) (16 740 lb) (15 840 lb) (17 645 lb)

Wooden blocks: 2 pcs. Size: 500 mm (L) × 500 mm (W) × 500 mm (H) (20 in) (20 in) (20 in) Fig. 10

Note: Each wooden block must be able to carry a load of at least 5 000 kg (11 000 lb).

Secure the arm cylinder rod with wire ropes and a lever block, as shown in Figs. 10 and 11.

Detail B Wire rope Lever block

Wire ropes: 2 pcs. 10 mmø × 3 000 mm (L) (0.4 inø) (117 in L) Lever blocks: 1 pc. for a 1 metric tonne (1.1 US ton) load

Wire rope

CAUTION: Securing this wire rope and lever block in place prevents the cylinder rods from being extended. Be sure to secure them, otherwise the cylinder may be extended suddenly, causing a serious accident.

Fig. 11

Detail C Urethane foam sleeve a

Note: The lever block secure the arm cylinders and prevent the cylinder rods from extending during the work.

Plated cylinder rod

Remove urethane foam sleeves a , fitted as protection on the plated arm cylinder rod.

Arm cylinder Fig. 12

Step 6 Preparation of the arm

Place wooden blocks under arm 09 as shown in Fig. 13. Arm 09 weight: STD H BE Semi long Long

09 5 065 mm 5 065 mm 4 410 mm 5 820 mm 6 820 mm

3 590 kg 4 010 kg 4 350 kg 3 900 kg 3 990 kg

(7 900 lb) (8 820 lb) (9 570 lb) (8 580 lb) (8 780 lb)

Wooden block

Wooden blocks: 2 pcs. Size: 500 mm (L) Ă&#x2014; 500 mm (W) Ă&#x2014; 500 mm (H) (20 in) (20 in) (20 in)

Fig. 13

Note: Each wooden block must be able to carry a load of at least 2 500 kg (5 500 lb). Bucket cylinder

1 2 3 4 5 6

Clean off the anticorrosive from the pins a and b inserted into the arm top. Extract the pins a and b from the arm top. Clean pin holes a and b . Clean off the anticorrosive applied to the pins c inserted into the arm. Extract pins c from the arm. Clean pin holes c and d in the arm.

Remove urethane foam sleeves e , fitted as protection on the plated bucket cylinder rod.

b a d

Fig. 14

Detail D Urethane foam sleeve e

Plated cylinder rod

Bucket cylinder Fig. 15

Fix bucket cylinder rods with wire ropes and a lever block as shown in Figs. 16 and 17.

Bucket cylinder

Wire ropes: 2 pcs. 10 mmø × 3 000 mm (L) (0.4 inø) (117 in L) Lever blocks: 1 pc. for a 1 metric tonne (1.1 US ton) load

Fig. 16

Detail E

Note: The lever blocks secure the bucket cylinders and prevent the cylinder rods from extending during the work.

Wire rope Lever block Wire rope

Bucket cylinder

Fig. 17

100

a x2

b x2

Step 7 Preparation of the bucket

Position bucket 10 .

Bucket 10 weight: 1.8 m3 2.0 m3 2.4 m3 2.8 m3 2.9 m3 3.4 m3 4.3 m3 3.4 m3 3.6 m3 4.3 m3

1 870 kg 2 060 kg 2 350 kg 2 400 kg 2 500 kg 2 650 kg BE 3 580 kg ROCK 3 460 kg BE-H ROCK 3 490 kg BE-ROCK 4 100 kg

(4 115 lb) (4 530 lb) (5 170 lb) (5 280 lb) (5 500 lb) (5 830 lb) (7 875 lb) (7 610 lb) (7 680 lb) (9 020 lb)

Fig. 18

Detail F

Clean pin holes a x2 and b x2, as shown in Fig. 18.

Reinstall the pins a and b removed from the arm, as shown in Fig. 19.

Set the O-rings 15 as shown in Figs. 19, 20 and 21.

O-ring 15 O-ring 15

Pin a

Pin b

Note: How to install O-ring 15

Fig. 19

Detail G 1

Remove the bolt and nut on O-ring 15 , slightly open the O-ring, and install it into the boss.

After installing O-ring 15 into the boss, temporarily tighten the bolt and nut. Bolt Nut

Nut O-ring 15

Bolt

Apply grease to the bucket pin holes and the connecting surfaces of the arm end and link (a total of 4 locations).

O-ring 15

Fig. 20

Fig. 21

Detail H Apply grease

Apply grease Fig. 22

101

Step 8

Lift

Installing the boom

Clean holes a in the boom boss. Grease the holes a on completion of cleaning.

1 2

Wire rope 18 mmø × 3 000 mm

Cleaning boom 08

Attaching wire ropes and chain block to boom 08 Attach wire ropes chain block and shackles to the boom as indicated in Fig. 23. Lift the boom, keeping holes a level.

1 2

Wire rope 18 mmø × 10 000 mm Chain block 5 ton

Wire rope 18 mmø × 12 000 mm

Wire rope 18 mmø × 3 000 mm

Note: Level the boom by adjusting the preset chain blocks.

CAUTION:

Boom 08

Under no circumstances should anyone enter underneath the lifted boom. Boom weight: Standard boom BE boom H boom Long boom

7 090 kg (15 600 lb) 7 200 kg (15 840 lb) 7 610 kg (16 740 lb) 8 020 kg (17 645 lb)

2 pcs.

Chain block (for 6 tonne load):

1 pc.

Moving the boom toward the base machine Slowly move the boom toward the base machine, keeping boom foot pin holes a at the same height as pin holes b in the main frame.

Fig. 23

Wire ropes: 4 pcs. 18 mmø × 3 000 mm (L) : 2 pcs. (0.7 inø) (117 in L) 18 mmø × 10 000 mm (L) : 1 pc. (0.7 inø) (390 in L) 18 mmø × 12 000 mm (L) : 1 pc. (0.7 inø) (468 in L) Shackle (for 6 tonne load):

Shackle

Lift Move

Cab

Rope

Notes: i)

Take care that the boom does not hit the cab. ii) Attach a rope to the boom end to guide it, as the lifted boom can sway unexpectedly. Rope: 1 pc. 8 mmø × (0.3 inø)

Hold

5 000 mm (L) (197 in L)

Installing the boom 1

Fig. 24

Align the pin holes in the boom foot and main frame. Insert the pin at location a and b .

Note: Grease the pin before insertion. Fig. 25

102

Shim

Check the size of clearance a between the boom foot boss and boom. If a is more than 3mm, fit the shim attached to the pin, on the side nearest the cab.

Detail I

t = 1.0 t = 2.3 Pin

Plate Clearance a Bolt, spring washer

Boom foot boss Fig. 26 Washer spring

After installing the pin, use bolts and spring washers to fit a plate to the pin end.

Plate

Bolt

Note: Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Fig. 27

Place a wooden block at the top of the boom, and lower the boom onto the wooden block. Lower

Wooden block: 1 pc. 100 mm (L) × 750 mm (W) × 50 mm (H) (4 in) (30 in) (2 in)

Wooden block Fig. 28

Remove the wire ropes and chain blocks and shackles attached to the boom. Remove the wire ropes

Fig. 29

103

Step 9 Connecting the hoses between the base machine and boom

Connecting the hoses

Cylinder hose a

Note:

※

Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure. Remove the caps from the piping ports and hoses.

Boom connection

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. Connect the 4 hoses a base machine to the boom. Check that the hoses do not contact the main frame, particularly at location . Note that it is sometimes the case that hoses hit against the travel device at with the boom cylinders fully extended. Perform an operational check in accordance with the instructions given on page 109.

2 3

Tightening torque:

1-1/2 hoses: 21 kgf·m (205 N·m/150 lbf·ft) 1-1/4 hoses: 14 kgf·m (140 N·m/100 lbf·ft)

Cylinder hose a

Fig. 30

After connecting the hoses, clean away any residue oil from the outside of all parts.

Detail J Pin

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to contact other parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 13 (P/No. 4510169) and 12 (P/No. 4508805) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

Step 10 Connecting the boom cylinder rods

Fig. 31

Do not pull the pins right out

Preparing the boom cylinder connection pins for boom cylinder connection 1

Pull the boom cylinder connection pins out from the boom before starting the work.

Note: Do not completely remove the pins, but leave the pin end attached to the outer edge of the bracket. 2 3

104

Clean away the anti-corrosive applied to the boom cylinder connection pins and pin holes. Apply grease to the pins and pin holes.

Fig. 32

Hold

Connecting each boom cylinder rod 1

Attach wire ropes to the boom cylinder and lift it.

Wire rope: 1 pc. 10 mmø × (0.4 inø) Scaffolding:

Plate

3 000 mm (L) (117 in L)

Spring washer Bolt

2 pcs.

Note: Make sure to use scaffolding to align the pin holes and insert the pins. A leader should be decided upon to direct the operation of both the base machine and the crane.

Start the engine and perform a boom raise operation to extend the boom cylinder rod such that the rod end aligns with the boom boss. Insert the pin and attach the plate with bolts and spring washers.

Scaffolding

Fig. 33

Wire rope 10 mm ø × 3 000 mm

Note: Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft) Fig. 34

Detail K Pin

Bolt, spring washer

Plate

Fig. 35

Fig. 37

Install the cylinder rod for the opposite side in the same manner. Fig. 36

105

Step 11 Connecting the boom cylinder grease hoses and electrical wiring

Connecting the boom cylinder grease hoses Attach the boom cylinder grease hose to the rod as indicated in Fig. 38.

Tightening torque:

6 kgfÂˇm (60 NÂˇm/45 lbfÂˇft)

Grease hose

Notes: i)

Make sure not to twist the hoses during installation as doing so can shorten their service life. ii) Install the hoses such that they do not contact other parts. iii) Check that the hose mating faces are free of dust and contaminants. iv) Make sure not to damage the hose mating faces during installation. 2 3

Fig. 38

Detail L Electric wire

Connect

Attach the grease hose for the opposite side in the same manner. After connecting the grease hoses, clean away any residue grease from the outside of all parts.

Connecting the electrical wiring at the boom bottom Connect the electrical wiring for the head lights as indicated in Fig. 39.

Fig. 39

Arm cylinder

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

Remove the lever blocks used to fix the arm cylinder in "Step 5- 2 " on page 98. (See Figs. 40 and 41)

Fig. 40

Detail M Wire rope Lever block

Wire rope

Fig. 41

106

Step 12

Detail N

Greasing (2)

IMPORTANT: c

Run the engine at medium speed or more when supplying grease using the lubricator.

2 3

Fig. 42

Start the engine.

Supply grease to 2 points as shown in Figs. 43 and 44. Supply grease to 4 points as shown in Figs. 45 and 46.

1 2

Fig. 43

Notes: i)

Detail O

BOOM CYL. BOTTOM

Fig. 44

Detail P

Fig. 45

BOOM CYL. ROD BOOM FOOT

Fig. 46

107

Lubrication method (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

d e

(2) Grab high-pressure grease gun b and pay out the hose from hose reel c to the length required.

Fig. 47

g f b

c Fig. 48

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.

h Fig. 49

108

Step 13 Checks

＊

Boom raise

Checking for hose interference Check that, when the boom is maximally raised and lowered, the hoses between the base machine and boom do not contact the central cover on the base machine or other peripheral devices, or hit against location indicated below. If there is hose interference, adjust the connection of affected hoses to the control valve. Problem area

CAUTION: When operating the boom, ensure that no-one other than the operator is in, on, or in the close vicinity of the machine. Hose

Fig. 50

Detail Q Problem area ※

Fig. 51

Step 14 Per-parathion bleeding the arm cylinder

＊

Bleeding the arm cylinder Lift the arm cylinder with a crane as indicated in Fig. 52, place block a under the lifted cylinder, and lower the arm cylinder back onto the block.

Lower

Block a

Fig. 52

109

Step 15 Air bleeding of boom and arm cylinder

Raise

Start the engine.

Lower

CAUTION: Make sure that nobody other than the operator is in or on the hydraulic excavator. 2 3 4

Idle the engine sufficiently to release the air in the hydraulic system. Check for unusual vibration or noise. Operate each cylinder a few times to bleed the air in the hydraulic system, according to the following procedure.

Note:

Fig. 53

The engine speed should be kept as low as possible. Retract Extend

Procedure

Action

Fig. 54

Start the engine.

Note: Run the engine at low speed. Move each cylinder back and forth five times.

Notes: i)

Avoid moving the cylinder suddenly or quickly, or the seals may be burnt. ii) Stop the cylinder 100 mm before the cylinder rod hits the stroke end during the first four cycles. iii) Move the cylinder at full stroke on the fifth cycle. 3

Hold the cylinder at the stroke end for a minute to apply relief pressure and bleed the air from the cylinder. Repeat the procedure twice. Stop the engine.

Bleeding Locations & Cylinder Positions for Bleeding Air

110

(Refer to next page)

Bleeding locations

CAUTION: Take all reasonable precautions as this work is to be conducted high above the ground.

Set the front-end attachment on the ground as illustrated below.

Stop the engine.

CAUTION: Take care to prevent anybody from starting the engine during the work. 3

Follow the procedures outlined below to release air from the cylinders, by way of each of the bleeders indicated by . 1) Remove the rubber cap. 2) Loosen the plug. 3) A mixture of air and hydraulic air will escape from the bleeder. 4) Continue bleeding until only oil escapes. 5) Tighten the plug securely. 6) Replace the rubber cap.

Arm cylinder

Boom cylinder Boom cylinder

Arm cylinder

Fig. 55

Detail R

Fig. 56

Detail S

Recheck the oil level in the hydraulic tank. If the oil level is low, refill the tank.

Level check

Fig. 57

111

Step 16 Installing the arm

Position the boom end about 3 500mm (135 in) above the ground.

Preparing the arm connection pin for installation 1

3 500 mm (135 in)

Pull arm connection pin a out from the boom end boss before starting the work.

Notes:

Fig. 58 Pin a

Do not completely remove the pin, but leave the pin end attached to the outer edge of the bracket. ii) A thrust plate is attached to the pin, which will be used in attaching the arm. 2 3

Clean away the anti-corrosive applied to the arm connection pin a . Apply grease to the pin and pin holes.

Attaching wire ropes to the arm 1 2 3

Remove pin b attached to arm 09 . Grease the pin and pin holes. Attach wire ropes, chain blocks and shackles to the arm and lift it as indicated in Fig. 60.

Arm weight: BE arm Long arm Standard arm H arm Semi-long arm

4 350 kg (9 570 lb) 3 990 kg (8 780 lb) 3 590 kg (7 900 lb) 4 010 kg (8 820 lb) 3 900 kg (8 580 lb)

Wire ropes: 4 pcs. 14 mmø × 10 000 mm (L) : 2 pcs. (0.55 inø) (390 in L) 14 mmø × 3 000 mm (L) : 4 pcs. (0.55 inø) (117 in L) Shackle (for 2.5 tonne load):

4 pcs.

Chain block (for 2.5 tonne load):

2 pcs.

Lift the arm, keeping holes c level.

Fig. 59 Hold

Wire rope 14 mmø × 3 000 mm

Wire rope 14 mmø × 10 000 mm

Shackle

Chain block 2.5 ton

Wire rope 14 mmø × 3 000 mm

c Shackle

Arm 09

Fig. 60

Lift

Note: Level the arm by adjusting the preset chain blocks.

CAUTION: Under no circumstances should anyone enter underneath the lifted arm. c Fig. 61

112

Lift

Moving the arm toward the boom 1

Move

Position 2 sets of scaffolding a as indicated in Fig. 62.

Scaffolding: Height about 3 000 mm × 2 pcs. (117 in)

b Arm

Note: Attach a rope to the arm end to guide it, as the lifted boom can sway unexpectedly. Rope: 1 pc. 8 mmø × (0.3 inø)

5 000 mm (L) (197 in L)

3 000 mm (117 in)

a Scaffolding

Rope

Fig. 62

2 3

Slowly move the arm toward pin holes b in the boom. Align the pin holes b from up on the scaffolding, in preparation to insert the pin. All subsequent work should performed from the scaffolding. Insert the pin. In inserting the pin, position either thrust plate c or d between the boom and arm, on both the left and right-hand sides. Ensure that the gap between the arm and boom is 1 mm (0.04 in) or less.

Hold

Fig. 63

Note: Exercise due caution in handling the pin as it is extremely heavy. Pin weight:

Hold

96 kg (210 lb)

CAUTION: Exercise due caution to avoid falling from the scaffolding. 5

Install the stopper. So as to prevent the pin from become removed, use 2 bolts and spring washers, and 1 plate to install a plate over the pin end.

Plate Spring washer Bolt

Fig. 64

Note: Apply lubricant to the bolts before installation.

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Detail T Pin

Thrust plate t = 2.0 c t = 1.0 d

Plate

Bolt, spring washer

Fig. 65

113

Position a wooden block under the arm end and slowly lower the arm to the ground.

Wooden block: 1 pc. 100 mm (L) × 750 mm (W) × 50 mm (H) (4 in) (30 in) (2 in) 7

Remove the wire ropes and chain blocks and shackles attached to the arm.

Lower

Remove the wire ropes and chain blocks and shackles attached to the arm.

Wooden block Fig. 66

Step 17

Lift

Installing the arm cylinder

Wire rope 10 mmø × 3 000 mm

Attaching wire rope to the arm cylinder 1

Lift the arm cylinder with a crane.

Wire rope: 10 mmø (0.4 inø)

Arm cylinder

3 000 mm (L) : (117 in L)

1 pc.

Gradually lift the arm cylinder such that the height of the arm cylinder and arm bracket pin holes coincide. Fig. 67

Start the engine and slowly extend the arm cylinder in the direction of the arrow until the arm cylinder rod and arm bracket pin holes align exactly. Hold Arm bracket pin hole

Arm cylinder

Inserting the pin 1 2

Grease the pin before insertion. Insert the pin.

Fig. 68

114

Install the stopper. Use 2 bolts and spring washers, and 1 plate to install a plate over the pin end. Pin

Note: Apply lubricant to the bolts before installation.

Plate Spring washer

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Bolt

Fig. 69

CAUTION: Exercise due caution to avoid falling from the scaffolding.

Detail U Pin

Plate

Bolt, spring washer

Fig. 70

Step 18 Connecting the arm cylinder grease hose

Attach the arm cylinder grease hose to the rod as indicated in Figs. 71 and 72. When connecting the grease hose to the arm cylinder rod, install the adapter facing sideways across the plane of the front-end to prevent the hose contacting the arm cylinder mounting bracket. Tightening torque:

6 kgf·m (60 N·m/45 lbf·ft)

Notes: i)

Fig. 71

Detail V Grease hose Avoid contact here

After connecting the grease hose, clean away any residue grease from the outside of all parts.

Fig. 72

115

Step 19 Connecting the bucket cylinder hoses and grease hoses

Note: Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure.

Bucket cylinder

Bucket cylinder hose

Remove the caps from the bucket cylinder hoses.

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. 2

Connect hoses 11 between the boom and bucket cylinder.

Fig. 73

Tightening torque: 14 kgf·m (140 N·m/100 lbf·ft)

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to contact parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 12 (P/No. 4508805) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

Install the bucket cylinder hose for the opposite side in the same manner.

Wire rope Lever block

Wire rope

After connecting the hoses, clean away any residue oil from the outside of all parts.

Removing the wire ropes and lever block used to fasten the bucket cylinder rod in "Step 6- 4 on page 100.

Fig. 74

116

Connect grease hoses at part a indicated by

Tightening torque:

Detail W

6 kgf·m (60 N·m/45 lbf·ft)

Notes: i)

When connecting hoses, do not twist them, or their service life will be shortened. ii) Connect the hoses so as not to contact parts. iii) Make sure that there is no dust sticking to the seat faces of the hoses. iv) Pay attention not to damage the joining surfaces of the hoses.

Fig. 75

After connecting the grease hose, clean away any residue grease from the outside of all parts.

Fig. 76

117

Step 20

Detail X

Greasing (3)

IMPORTANT: c

Run the engine at medium speed or more when supplying grease using the lubricator.

2 3

Fig. 77

Start the engine.

Supply grease to 1 point as shown in Figs. 78 and 79. Supply grease to 4 points as shown in Fig. 80.

Fig. 78

Notes:

Detail Y

ARM CYL. BOTTOM

Fig. 79

Detail Z

BOOM AND ARM JOINT ARM CYL. ROD BUCKET CYL. BOTTOM

Fig. 80

118

Lubrication method (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

d e

(2) Grab high-pressure grease gun b and pay out the hose from hose reel c to the length required.

Fig. 81

g f b

c Fig. 82

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.

h Fig. 83

119

Step 21 Air bleeding of arm and bucket cylinder

Roll out

Start the engine.

Retract Roll in

Extend

CAUTION: Make sure that nobody other than the operator is in or on the hydraulic excavator. 2 3 4

Fig. 84

Note: The engine speed should be kept as low as possible.

Procedure

Action 1

Start the engine.

Note: Run the engine at low speed. 2

Move each cylinder back and forth five times.

Notes: i)

Hold the cylinder at the stroke end for a minute to apply relief pressure and bleed the air from the cylinder. Repeat the procedure twice. Stop the engine.

Bleeding Locations & Cylinder Positions for Bleeding Air

120

(Refer to next page)

Bleeding locations

CAUTION: Take all reasonable precautions as this work is to be conducted high above the ground.

Set the front-end attachment on the ground as illustrated below.

Stop the engine.

CAUTION: Take care to prevent anybody from starting the engine during the work. 3

Arm cyl. Arm cyl.

Bucket cyl.

Fig. 85

Detail A

Fig. 86

Detail B

Recheck the oil level in the hydraulic tank. If the oil level is low, refill the tank.

Level check

Fig. 87

121

Step 22 Bucket installation

Preparing the bucket for installation 1 2

Apply grease to pin holes a and b . Apply grease to pins c and d .

b Fig. 88

1 2

Check O-rings 15 to the inside of the boss (4 positions). Clean face before installing the O-rings.

C C'

Fig. 89

Section C 15

Fig. 90

122

Lift

Attaching wire ropes to the bucket 1

Attach wire ropes and chain block to bucket 10 as indicated in Fig. 91.

Wire rope 14 mmø × 3 000 mm

Notes: i)

Attach protectors to positions a (see Fig. 91) to avoid damaging the bucket. ii) Level the bucket by adjusting the preset chain blocks.

Wire rope 14 mmø × 10 000 mm

Chain block 2 ton Wire rope 14 mmø × 3 000 mm

CAUTION:

Never allow anybody to stand directly beneath the lifted bucket. b 2

Lift the bucket, keeping holes b level.

Bucket weight: 1.8 m3 2.0 m3 2.4 m3 2.8 m3 2.9 m3 3.4 m3 4.3 m3 3.4 m3 3.6 m3 4.3 m3

1 870 kg 2 060 kg 2 350 kg 2 400 kg 2 500 kg 2 650 kg BE 3 580 kg ROCK 3 460 kg BE-H ROCK 3 490 kg BE-ROCK 4 100 kg

(4 115 lb) (4 530 lb) (5 170 lb) (5 280 lb) (5 500 lb) (5 830 lb) (7 875 lb) (7 610 lb) (7 680 lb) (9 020 lb)

Bucket 10 Fig. 91

Wire ropes: 3 pcs. 14 mmø × 10 000 mm (L) : 1 pc. (0.55 inø) (390 in L) 14 mmø × 3 000 mm (L) : 2 pcs. (0.55 inø) (117 in L) Protector:

2 pcs.

Chain block (for 2.5 tonne load):

1 pc. 2 500 mm (98in)

Fig. 92

Position the arm end around 2 500mm (98 in) above the ground.

Lift Move

Moving the bucket to the arm 1

Lift the bucket to a height such that pin holes c in the arm end are level with pin holes d in the bucket. Move the bucket to pin holes d .

Fig. 93

123

Hold

Inserting the bucket pins

Note: Before inserting the pins, measure the clearance between the bucket and arm, to check that it is between 1 and 2mm. For details, refer to the following page. 1 2

Align the pin holes in preparation for inserting the pins. Insert the pin. Insert thrust plates 14 and 16 between the bucket and the arm to adjust the clearance.

Bolt

Spring washer Stopper Pin

Notes: i) Apply grease to the pins before insertion. ii) Refer to the following page for details of the thrust plate adjustment procedure. 3

Install the stopper using bolts and spring washers.

Fig. 94

Detail D

Stopper Bolt, spring washer

Note: Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft) Pin

Note: Make sure to adjust clearance (a) to bring it into the range 1 to 2mm.

Fig. 95

Detail E Arm

O-ring 15

Set O-rings 15 in the groove between the bucket and the arm. Bucket

Note: Be careful to avoid damaging the O-rings on the boss of the arm. 2

Thrust plate

14 and/or 16

(a)

Fig. 96

Tighten the nuts of O-rings 15 .

Tightening torque:

Detail F

0.6 kgf·m (6 N·m/4.3 lbf·ft)

Note: The longer bolt makes the O-ring easier to assemble. After assembly, cut it into ☆ 10~20 mm length. (Bolt size: M5) ☆ 10 ~ 20

☆ 10 ~ 20 Slit

O-ring 15 Double nut

Double nut Fig. 97

Assemble the O-ring so that no gap is left here.

124

REFERENCE: Adjusting the Bucket Linkage The machine is provided with a bucket adjustment system to take up play in the linkage. When play in the linkage increases, remove and install shims as follows: 1 2 3

Park the machine on a level surface. Lower the bucket to the ground with the flat side down so the bucket will not roll. Run the engine at slow idle. With the bucket on the ground slowly swing counterclockwise slightly until the top of the left bucket boss contacts the arm. Stop the engine. Pull the pilot control shut-off lever to the LOCK position.

Note: Bolts a does not need to be removed to remove shims. Shims are of a split type that can be easily pushed off with a screwdriver after bolts a have been loosened. 4 5

Slightly loosen four (M14) bolts a using a 30 mm (1.17 in) wrench. Remove all shims c from clearance (C) between plate b and bucket. Push and hold bolts a to remove all clearance (A) between the arm and boss d . Holding boss d against arm increases clearance (B). Measure distance (B) using a feeler gauge.This distance should not be adjusted below 0.5 mm (0.02 in). Install as many shims c into clearance (B) as possible.

Note: Remaining shims c must be installed in clearance (C) to prevent arm end face or bolt damage. 7

Install remaining shims c into clearance (C) and tighten bolts a to 14 kgf·m (140 N·m/100 lbf·ft).

Note: The total number of shims c used is 5. 8

Replace boss d if measurement (D) is 5 mm (0.2 in) or less. NOTE: The BE and HD buckets do not have this adjusting machine.

Detail G

Location of clearance adjustment

d Arm Bucket

Pin Groove width (D)

Clearance (A) Clearance (B)

Clearance (C) Bucket

Fig. 98

125

Extend the bucket cylinder

Adjusting the arm angle 1 2

Set the arm angle to between 120° to 140°. Extend the bucket cylinder such that pin hole a of the bucket link aligns with pin hole b of the bucket.

0 12

o ˚t

0˚ 14

Connecting the bucket and link 1 2

Carefully align the link and bucket pin holes. a Insert the pin. b

a b

Note: Grease the pin before insertion. 3

To prevent the pin from becoming removed, install stopper over the pin ends using bolts and spring washers.

Fig. 99

Fig. 100

Note: Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft) 4

Set O-rings 15 in the groove between the bucket and links.

Note: Be careful to avoid damaging the O-rings on the boss of the links. 5

Bolt Spring washer

Tighten the nut on O-ring 15 .

Stopper

Tightening torque:

0.6 kgf·m (6 N·m/4.3 lbf·ft)

Detail J Fig. 101

Detail H

O-ring 15

Bolt, spring washer

Fig. 104

Note: The longer bolt makes the O-ring easier to assemble. After assembly, cut it into ☆ 10~20 mm length. (Bolt size: M5) Slit

Assemble the O-ring so that no gap is left here.

Detail I

☆ 10 ~ 20

Double nut

Fig. 102

Link O-ring 15

Double nut

Bucket

Fig. 103

126

Step 23

Reinstall the handrail and adjusting the rearview mirror

Reinstalling the removed handrail Reinstall the handrail a removed on page 75 of the base machine assembly instructions. Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: Apply lubricant to the threads of the mounting bolts. ii) Hand screw in all bolts first, before tightening to the specified torque.

Fig. 105

Rear view mirror

Adjusting the rear view mirror Adjust the rear view mirror Check that the operator gets a clear view of the rear of the machine from the operator’s seat. Tightening torque:

1 kgf·m (10 N·m/7.2 lbf·ft) Fig. 106

Step 24 Installing the lamp 1

Put bracket-fitted lamps 17 on the right and left side of the boom.

Tightening torque:

Detail K 17

5 kgf·m (50 N·m/35 lbf·ft)

Connect the electric wire couplers a and b .

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

b Fig. 107

127

Step 25

Detail L

Greasing (4)

IMPORTANT: c

Run the engine at medium speed or more when supplying grease using the lubricator.

Note: Bucket and Link Pins Each grease fitting is provided with a protective cap. Remove cap as shown below before greasing. Removing/installing procedure: Insert a screw driver into the cap cavity along the arrow e direction, and scoop out the cap by applying force in the arrow f direction. When installing, push the cap by hand in the arrow g direction until it bottoms or tap using screw driver grip.

Fig. 108

Cap Head

Grease Fitting Cap

f e Pin

Cavity Screw Driver Fig. 109

Start the engine.

Supply grease to 9 points as shown in Fig. 110.

Detail M

Notes: i)

Fig. 110

128

Lubrication method d (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

Fig. 111

(2) Grab high-pressure grease gun b and pay out the hose from hose reel c to the length required. (3) Press hydro-chuck g protruding from highpressure grease gun b into a grease nipple and pull the lever to discharge grease. (4) Release the lever when greasing is complete; grease discharge will stop.

g f b

Fig. 112

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. h

Fig. 113

After the oil has run out, clean the parts carefully.

129

7-3 Bleeding the cylinders and checking the hydraulic system Step 1 Bleeding the hydraulic cylinders

Boom raise Arm roll-out

Start the engine. Arm roll-in

CAUTION: Make sure that nobody other than the operator is in or on the hydraulic excavator.

2 3 4

Bucket roll-out

Boom lower

Bucket roll-in

Fig. 1

Note: The engine speed should be kept as low as possible.

Procedure

Action Start the engine.

Note: Run the engine at low speed. Move each cylinder back and forth five times.

Notes: i)

Hold the cylinder at the stroke end for a minute to apply relief pressure and bleed the air from the cylinder. Repeat the procedure twice. Stop the engine.

Bleeding Locations & Cylinder Positions for Bleeding Air

130

(Refer to next page)

Step 2 Bleeding locations

CAUTION: As this work is to be conducted at a height, take due safety precautions.

1 2

Set the front-end attachment on the ground in the position illustrated below (Fig. 2). Stop the engine.

CAUTION: Take care to prevent anybody from starting the engine during the work. 3

Following the procedure outlined below, release the air from the cylinders, by way of the bleeding locations indicated by . 1) 2) 3) 4) 5) 6)

Remove the rubber cap. Loosen the plug. Air and hydraulic oil will escape together. Continue bleeding until only oil escapes. Tighten the plug securely to its original position. Replace the rubber cap. Bucket cylinder bottom

Arm cylinder rod

Bucket cylinder rod

Arm cylinder bottom

Boom cylinder rod

Boom cylinder bottom

Fig. 2

Detail A

Level check

Recheck the oil level in the hydraulic tank. If there is insufficient oil, refill the tank through the oil filler port. Position the front-end attachment as illustrated in Fig. 4 when checking the oil level.

Fig. 3

Fig. 4

131

7-4 Adjusting the track link tension

Adjusting the track link tension 1

Rotate the superstructure 90°, and tilt the machine over to one side by lowering the bucket. Make sure to keep the angle between the arm and boom in the range 90° to 110°, and place the rounded front of the bucket flat against the ground during this procedure. Place wooden blocks under the main frame to support the machine, as indicated in Fig. 1.

90° ~ 110°

Wooden blocks: 2 pcs. 1 200 mm (L) × 800 mm (W) × 1 000 mm (H) (47 in) (31 in) (39 in) 3

Rotate the uplifted track link forwards through 2 turns, and then backwards through 2 turns.

Fig. 1 Wooden block

Detail A

Measuring the distance between the top of the lower shoes, and the bottom of the track frame. Measure the distance between the base of the track frame and the back of the track shoes, at the center of the track frame. The standard distance is as detailed below.

Note: L

Remove any rocks and other debris caught in the sprockets. (Length L) Standard tension

Fig. 2

460 ~ 510 mm (18 ~ 20 in)

To loosen the track link tension, slowly loosen valve a (24mm hex) to release excess grease. 1 to 1.5 turns of the valve should be sufficient. If grease does not escape at a constant rate, slightly rotate the uplifted track link. Tighten valve a on completion of adjusting the track link tension. Tightening torque: 15 kgf·m (150 N·m/110 lbf·ft)

Detail B

CAUTION: Over-loosening valve a or loosening the valve overabruptly can cause the valve to fly off the machine or pressurized grease to shoot from the valve, due to the adjuster cylinder being highly pressurized. Make sure to keep your face and body parts well away from valve a , and to loosen the valve slowly. Under no circumstances should grease fitting b be loosened.

Adjusting the track link tension 1

132

If the track link tension is outside the range of the standard tension, tighten or loosen the track link appropriately (see the next page). After adjusting both the left and right track links, equalize the left and right track link tensions by driving the machine forward and backward. Recheck the track link tension. If the tension is outside the range of the standard value, readjust the track links.

Fig. 3

Detail C a b

Grease outlet

Fig. 4

Detail D Loosen the Track b

CAUTION: Do not loosen valve a quickly or loosen it too much as high-pressure grease in the adjusting cylinder may gush out. Loosen carefully, keeping body parts and face away from valve a . Never loosen grease fitting b .

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it before loosening.

To loosen the track, slowly turn valve a counterclockwise using long socket 24; grease will escape from the grease outlet.

Between 1 to 1.5 turns of valve a is sufficient to loosen the track.

If grease does not drain smoothly, slowly rotate the raised track.

Fig. 5

Grease Outlet

When the proper track sag is obtained, turn valve a clockwise and tighten to 15 kgf·m (150 N·m/110 lbf·ft).

Fig. 6

Detail E Tighten the Track

CAUTION: It is abnormal if the track to remains tight after turning valve a counterclockwise or it the track is still loose after charging grease to fitting b . 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 b and add grease until the sag is within specifications.

Fig. 7

133

7-5 Final trial operation check Step 1

Detail A

After check

After connecting all the hoses, check that no hose hits against other hose or parts.

Adjust the track link tension appropriately. (See pages 132 and 133 "Adjustment of track link tension".)

Check all functions of the machine. (See "Checks after completing the assembly")

Recheck the oil level in the hydraulic tank. If there is insufficient oil, refill the tank through the oil filler port.

CAUTION: Before starting, make sure there is no person other than the operator in the hydraulic excavator.

Fig. 1

Note: After the above procedures 1 and 2 are completed, carry out work at 60% to 70% of full power for the first 50 operating hours, before commencing full-power operation.

Fig. 2

Step 2 Final checks for the backhoe front-end

Thoroughly clean any oil from the machine with rags.

Detail B

On full completion of the backhoe assembly, recheck that all bolts are tightened to the specified torque.

Fig. 3

134

7-6 Backhoe lubrication

Lubrication Lubricating points and grease types After assembling the backhoe front-end, lubricate the points illustrated in Fig. 1.

Select an appropriate grease type according to the following table.

Brand Name of Recommended Grease Application Air Temp.

Manufacturer

Fig. 1

Bucket, Arm and Boom, Swing Gear, Swing Bearing, etc. − 20 to 40°C (− 4 to 104°F)

Hitachi Genuine

Doubrex SEP Grease

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 EP Grease

Locations requiring lubrication

Note: On shipment from the factory, the machine is filled with the lubricant marked .

No.

Front joint pins (around bucket)

Front joint pins (other than around bucket)

135

Lubrication method Lubrication with the lubricator The machine is fitted with a lubricator and hose reel, which can be used for easy-operation pneumatic lubrication. a

CAUTION:

Lubrication of the top of the boom and arm is performed at height. Take appropriate measures to avoid falling from the machine.

Note:

Set the engine to run at medium idle or higher when using the lubricator.

Lubricator Operation 1

Turn power switch d ON to activate the pump. Grease is sucked up and supplied to highpressure grease gun b .

Fig. 2

CAUTION: When the pump starts up, any air trapped inside pump a will be mixed in, with the discharged air making the grease turn whitish. Open check valve cock e to bleed this aerated grease. Securely close check valve cock e when all aerated grease has bled out. 2 3

Hold high-pressure grease gun b and pay out the hose from hose reel c to the length required. Press hydro-chuck g protruding from highpressure grease gun b into the grease nipple, and pull the lever to discharge grease. Release the lever when greasing is complete; grease discharge will stop.

CAUTION:

g f b

When detaching hydro-chuck g from grease nipple h , grease nipple h tip may break unless special care is taken, as follows: â&#x20AC;˘ Tilt nozzle f a little so as to release the connecting pressure applied to hydro-chuck g . â&#x20AC;˘ Slowly detach hydro-chuck g from nipple h . 5

When all greasing work is complete, turn power switch d OFF, then pull grease gun lever to release any remaining pressure from grease gun b , pump a , and the hose so as to ensure long component life. A little grease will be discharged at this time.

Fig. 3

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.

136

h Fig. 4

NOTES

137

NOTES

138

ZX800/ZX850H Assembly Manual

LOADER FRONT

ATTACHMENTS

MOUNTING PROCEDURE FOR FRONT-END ATTACHMENTS

8. Loader front mounting procedure 8-1 Preparation

Loader front assembly flowchart

Fig. 1

Step 1

Parts required Item No. Shipping Part List

Part No.

00 01 02 03 04 05 06 07

4331075 4331076 4089703 M341445 4450978 4414282 4508805 4187328

(22) (23) (25) (26) (28) (29) (30) (31) (

Part name CYL., BOOM (R) CYL., BOOM (L) FLANGE; SPLIT BOLT; SOCKET HOSE HOSE O-RING O-RING

Qâ&#x20AC;&#x2122;ty 1 1 8 16 2 2 6 2

Remarks

Boom cyl. Boom cyl. rod Boom cyl. bottom Boom cyl. bottom + rod Boom cyl. rod

) No. on Shipping part list

141

Item No. Shipping Part List

Part No.

08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

——— ——— ——— 4405604 Z966993 4318402 4508805 4508805 4421535 4162704 4102702 Z425176 3096646 3074182 J901211 J950012 Z449490 4441974 4508805

(00) (02) (04) (06) (07) (09) (10) (12) (13) (14) (15) (17) (19) (20) (21) (22) (23) (25) (26) (

Part name BOOM/ARM LINKAGE BUCKET, LOADER LAMP ASS’Y HOSE O-RING HOSE O-RING O-RING HOSE O-RING RING CORK CLAMP, HOSE CLAMP BOLT NUT WASHER HOSE O-RING

) No. on Shipping part list

142

Q’ty 1 1 2 2 4 2 4 12 2 2 2 2 2 4 9 18 18 6 12

Remarks Includes boom, arm, arm cylinder, level cylinder, tilt cylinder, and links A&B 4.0 Bucket For the front-end (with mounting bolts) 1" Base machine-front end 1" 1"-1/4" Base machine-front end 1"-1/4" 1"-1/4" 1"-1/4" Front end-bucket Arm end Arm end For plugging the eye bolt mounting hole in the tilt cylinder For hoses between the base machine and boom For hoses between the boom and arm For securing the clamps

For boom to arm

8-2 Mounting the loader front Step 1

Note: Do not completely detach the pin

Preparing the base machine

Preparing the base machine Remove the boom foot pin fitted to the base machine.

Notes: i)

Fig. 1

Clean away the anti-corrosive applied to the boom foot pin and pin holes. Apply grease to the boom foot pin and pin holes.

Lift

Step 2 Wire rope 12 mmø × 5 000 mm

Installing the boom cylinders

Attaching wire ropes to the boom cylinders 1

Attach wire ropes to boom cylinder (L) 01 as indicated in Fig. 2.

Boom cylinder weight: Wire ropes: 12 mm × (0.45 in)

700 kg (1 540 lb)

5 000 mm (L) : (195 in L)

2 pcs. 01

Clean away the anti-corrosive applied to bottom and rod boss a and b of the boom cylinder. Apply grease to boss a and b .

1 2

Lifting boom cylinder 01 Lift the boom cylinder, keeping it level.

Fig. 2

b Hydraulic piping

Note: The left and right boom cylinders differ in the manner depicted in Fig. 3. Be sure not to mix them up.

Right boom cylinder 00

Left boom cylinder 01

Fig. 3

143

Preparing the boom cylinder foot pins for installation Remove boom fit pins a and b fitted to the base machine.

Notes: i)

Do not completely remove the pins, but leave the pin end attached to the inside of the insidefacing bracket. ii) Shims are attached to foot pins a and b , which are to be used during pin installation. 2 3

Clean away the anti-corrosive applied to the boom foot pins and pin holes. Apply grease to the boom foot pins and pin holes.

Installing boom cylinder (L) 01 1

a Fig. 4 Hold

Move

Move the boom cylinder toward the base machine, such that the bottom boss of the boom cylinder aligns with the frame boss.

Bolt Spring washer Plate

Note:

Install the boom cylinder such that the hydraulic piping faces downward. 2 3

4 5

01 Install the boom cylinder with the hydraulic piping facing downward. Fig. 5

Detail A

Shim

Plate

Note:

Clearance

Apply lubricant to the pin before installation.

Bolt, spring washer

Cab side

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Lower the boom cylinder onto a cylinder support such that it is maintained level. Install boom cylinder 00 in the same manner as described above.

Fig. 6

Note: Place a V-block shaped rest under the top of the boom cylinders to protect the hydraulic piping. Cylinder support: 1 pc. Height: 1 800 mm (70 in) V-block:

01 V-block Cylinder support

2 pcs.

Fig. 7

144

Step 3 Boom cylinder rod hoses 04 (In side)

Connecting the boom cylinder hoses

Boom cylinder bottom hoses (Out side)

Note: Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure. Remove the caps from the ends of the hoses.

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. Connect the 4 boom cylinder hoses 04 and 05 between the boom cylinders and base machine. Use split flange 02 and socket bolts 03 during this work.

Tightening torque: 14 kgfÂˇm (140 NÂˇm/100 lbfÂˇft)

Fig. 8

Notes: i) ii) iii) iv) v)

After connecting the hoses, clean away any residue oil from the outside of all parts.

Step 4 Bleeding the boom cylinders

Boom cylinder

Notes: i)

Fig. 9

After completely bleeding the boom cylinders of air, retract them in preparedness for the next step.

145

Step 5 Preparing the boom for installation

Detail B

Place wooden blocks under the boom linkage (L/D front) 08 as shown in Figs. 10 and 11.

Wooden blocks: 2 Size: 500 mm (L) × 500 mm (W) × 500 mm (H) (20 in) (20 in) (20 in)

Fig. 11

08 b

Clean the pin holes a of the boom foot indicated by . Clean the pins b for the boom cylinder indicated by .

2 3

Fig. 10

Wooden block

Installing hoses to boom linkage. Remove the caps from the ends of the hoses.

Hose 25

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released.

Connect the 6 hoses 25 between the arm and boom. (See Figs. 12 and 13)

Tightening torque: 14 kgf·m (140 N·m/100 lbf·ft) Fig. 12

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to make contact with other parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 26 (P/No. 4508805) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

146

21 22 23 24 25

700 mm (27 in)

Fit clamps 21 to the hoses, using bolts 22 , nuts 23 and washers 24 , as indicated in Fig. 13.

Tightening torque:

Detail C

9 kgf·m (90 N·m/65 lbf·ft)

After connecting the hoses, clean away any residue oil.

Fig. 13

Step 6 Preparation of the loader bucket

Position loader bucket 09 as indicated in Fig. 14.

Bucket assembly weight: 3.6 m3 Bottom dump bucket 4.0 m3 Bottom dump bucket 4.0 m3 Tilt dump bucket 4.4 m3 Tilt dump bucket

6 080 kg 5 620 kg 4 980 kg 4 630 kg

(13 380 lb) (12 365 lb) (10 960 lb) (10 190 lb)

b 2 3 4

Clean pins a and b in bucket 09 . Extract pins a and b from the bucket. Clean pin holes a and b on the bucket.

Fig. 14

c 09

Remove cover c as shown in Fig. 15.

Fig. 15

Set pins d and e , previously removed from the bucket, as shown in Fig. 16.

Set the 2 O-rings 17 and 2 rings 18 as shown in Fig. 16 and 17.

Bucket

View D

17 18

O-ring 17 Ring 18

Fig. 16 Fig. 17

Apply grease to bucket pin holes f and g and the connecting surfaces of the arm end (a total of 8 locations) as shown in Fig. 18.

View E f

Fig. 18

147

Remove urethane foam sleeves a , fitted as protection on the plated dump cylinder rod.

Detail F

Dump cylinder Urethane foam sleeve a

Plated cylinder rod

Dump cylinder Fig. 20

148

Fig. 19

Lift

Step 7 Wire rope 26 mm × 3 000 mm

Installing the boom

Attaching wire ropes to the boom 1

Attach wire ropes and chain block to boom 08 as indicated in Fig. 21.

Loader boom weight:

11 100 kg (24 420 lb)

Chain block 6 ton

Wire rope 26 mm × 10 000 mm

Wire rope 26 mm × 3 000 mm

Wire ropes: 3 pcs. 26 mmø × 10 000 mm (L) : 1 pc. (1.0 inø) (390 in L) 26 mmø × 3 000 mm (L) : 2 pcs. (1.0 inø) (117 in L) Shackle (for 6 tonne load): Chain block (for 6 tonne load): 2

Shackle

2 pcs.

1 pc.

Lift the boom, keeping holes a level.

Note: Level the boom by adjusting the preset chain blocks.

Fig. 21

CAUTION: Under no circumstances should anyone enter the area beneath the lifted boom.

Lift Move

Moving the boom Slowly move the boom toward the base machine, keeping boom foot pin holes a at the same height as pin holes b in the main frame.

Notes:

Cab

i) Take care that the boom does not hit the cab. ii) Attach a rope to the boom end to guide it, as the lifted boom can sway unexpectedly.

Rope

Rope: 1 pc. 8 mmø × (0.3 inø)

5 000 mm (L) (197 in L)

Fig. 22 Hold

Installing the boom 1 2

Align the pin holes in the boom foot and main frame. Insert the pin at location a and b . a

Note: Grease the pin before insertion.

Fig. 23

149

Shim

Check the size of clearance a between the boom foot boss and boom. If a is more than 3mm (0.1 in), fit the shim attached to the pin, on the side nearest the cab.

Detail G

t = 1.0 t = 2.3 Pin

Plate Clearance a Bolt, spring washer

Fig. 24

After installing the pin, use bolts and spring washers to fit a plate to the pin end.

Spring washer Plate

Bolt

Note: Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Fig. 25

Place a wooden block at the top of the boom, and lower the boom onto the wooden block.

Lower

Wooden block: 1 pc. 100 mm (L) × 750 mm (W) × 50 mm (H) (4 in) (30 in) (2 in)

Wooden block

Fig. 26

Remove the wire ropes and chain block attached to the boom. Remove the wire ropes and chain block

Fig. 27

150

Step 8

11 13

Connecting the hoses between the base machine and boom

Note: Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure.

Connecting the hoses Remove the caps from the travel motor ports and travel hoses.

CAUTION: In removing the caps from the hose ends, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released.

Fig. 28

Detail H

Connect the 4 hoses 11 and 13 between the base machine and the boom.

Tightening torque: 14 kgf·m (140 N·m/100 lbf·ft)

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to make contact with other parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 12 (P/No. Z966993) and 14 (P/No. 4508805) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

Detail I

20 22 23 24

Fit clamps 20 to the hoses, using bolts 22 , nuts 23 and washers 24 , as indicated in Fig. 30. Tightening torque:

Fig. 29

9 kgf·m (90 N·m/65 lbf·ft)

After connecting the hoses, clean away any residue oil.

Fig. 30

151

Detail J Step 9

Connecting the boom cylinder rods

Preparing the boom cylinder connection pins for boom cylinder connection Fig. 31

Pull the boom cylinder connection pins out from the boom before starting the work.

Do not completely remove the pins

Note: Do not completely remove the pins, but leave the pin end attached to the outer edge of the bracket. 2 3

Clean away the anti-corrosive applied to the boom cylinder connection pins and pin holes. Apply grease to the pins and pin holes.

Connecting each boom cylinder rod 1

Fig. 32

Lift

Attach wire ropes to the boom cylinder and lift it.

Wire rope: 1 pc. 10 mmø × (0.4 inø)

Wire rope 10 mmø × 3 000 mm

3 000 mm (L) (117 in L)

Note: Make sure to use scaffolding to align the pin holes and insert the pins. A leader should be decided upon to direct the operation of both the base machine and the crane. Fig. 33

Scaffolding

Start the engine and perform a boom raise operation to extend the boom cylinder rod such Plate that the rod end aligns with the boom boss. Insert the pin and attach the plate with bolts and spring Spring washers.

Lift

washer

Note:

Bolt

Apply lubricant to the bolts before installation. Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Fig. 34

Install the cylinder rod for the opposite side in the same manner.

Detail K Pin

Bolt, spring washer

Plate

Fig. 35

152

Step 10 Connecting the boom cylinder grease hoses and electrical wiring

Connecting the boom cylinder grease hoses Attach the boom cylinder grease hose to the rod as indicated in Fig. 36.

Tightening torque:

6 kgfÂˇm (60 NÂˇm/45 lbfÂˇft) Grease hose

Notes: i)

2 3

Fig. 36

Attach the grease hose for the opposite side in the same manner. After connecting the grease hoses, clean away any residue grease from the outside of all parts. Fig. 37

Connecting the electrical wiring at the boom bottom Connect the electrical wiring for the head lights as indicated in Fig. 38.

Detail L Electric wire

Note: Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers.

Connect

Fig. 38

153

Step 11 Preparing for bucket installation

Level cylinder

Remove stopper a attached to the level cylinder before shipment.

CAUTION:

If the boom/arm linkage is lifted with stopper a removed, the arm and level cylinders can retract unexpectedly, possible leading to personal injury.

Fig. 39

Tilt cylinder

b 1

Hold the tilt cylinders shown in Fig. 41, with a crane.

Fig. 40

Wire rope: 10 mmø × 3 000 mm (L) : 1 pc. (0.4 inø) (117 in L) 2 3 4

5 6 7

Remove shackles d and eye bolts e , used to secure the bucket cylinders to the arm. Lower the crane that is holding the tilt cylinders as outlined in step 1 , as shown in Fig. 42. Fit corks 19 (P/No. Z425176) to the tilt cylinders to plug the eye bolt e mounting holes. Hold links b with a crane (Fig. 40). Remove wire c used to fasten the links b and tilt cylindes at the time of shipping. Remove the crane that is holding links b .

Detail N

Holt

Arm

Detail N' e

Arm Lower

Tilt cylinder

Fig. 41

Fig. 42

Note: Store stopper a , wire ropes c , shackles d and eye bolts e away in a safe place, as they will be required during subsequent transportation of the machine.

CAUTION

CAUTION: Under no circumstances should the front-end cylinders be operated with the tilt cylinders in a secured state, as the bucket cylinders could move unexpectedly and lead to serious personal injury.

Fig. 43

154

Detail M

CAUTION: Precautions for the loader front with the bucket unattached Exercise due care in operating the loader front with the bucket unattached, as excessive forces can be applied to the tilt cylinders and arm as depicted to right, potentially damaging them. Under no circumstances should the following operations be performed: Arm roll-out with the tilt cylinders retracted. Bucket roll-in with the arm cylinders extended.

Arm

Tilt cylinder

Fig. 44

Arm roll-in with the tilt cylinders extended. Bucket roll-out with the arm cylinders retracted.

CAUTION

Fig. 45

Fig. 46

155

Step 12

Level cylinder

Bleeding the tilt cylinders

ďź&#x160;

Arm cylinder

Bleed the arm and tilt cylinders in the following manner so as to avoid damaging the cylinder seals. Start the engine and run the machine at low idle. Bleed the tilt cylinders by operating the arm and then the bucket lever to slowly extend and retract the arm and tilt cylinder rods, respectively. Continue bleeding the cylinders until they operate smoothly. Fig. 47

Note: Avoid operating the cylinders jerkily, rapidly or in any other way which could damage the cylinder seals. Tilt cylinder

Note: Confirm that the bucket cylinder link is perpendicular to the arm when operating the arm and tilt cylinders.

Detail O

Arm Fig. 48

Link

Perpendicular

Fig. 49 Tilt cylinder

CAUTION: Avoid extending the cylinders to stroke end, as doing so causes abnormally high stresses to be applied to the cylinders and cylinder links, potentially leading to damage to that cylinder.

Fig. 50

CAUTION: When operating the boom, ensure that no-one other than the operator is in, on, or in the close vicinity of the machine.

Fig. 51

156

Step 13

Detail P

Greasing (2) a

IMPORTANT: c

Run the engine at medium speed or more when supplying grease using the lubricator.

2 3

Fig. 52

Start the engine.

Supply grease 8 to points as shown in Figs. 53 and 54. Supply grease 2 to points as shown in Figs. 55 and 56.

Fig. 53

Notes: i)

Detail Q

Fig. 54

Detail R

Fig. 56 Fig. 55

157

Lubrication mouthed (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

d e

Fig. 57

g f b

c Fig. 58

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.

h Fig. 59

158

Step 14 Installing the bucket

Preparing bucket 09 for installation 1 2

Apply grease to pin holes a , b , c and d . Apply grease to pins c and d . 09 d

b a Fig. 60

Check 2 O-rings 17 and 2 rings 18 to the inside of the boss (2 positions). Clean face â&#x20AC;ť before installing the O-rings.

S 09

Fig. 61

Section S Bucket

O-ring 17 Ring 18 â&#x20AC;ť Clean this face

Fig. 62

159

Detail T

Attaching wire ropes to bucket 09 1 2

Attach shackles to the bucket eye plates, and attach wire ropes and a chain block to the bucket. Lift the bucket as indicated in Fig. 63.

Wire rope 18 mmø × 10 000 mm

Chain block 6 ton

Bucket weight: Bottom dump type rock bucket 3.6 m3 :

6 080 kg (13 380 lb) Bottom dump type general purpose bucket 4.0 m3 : 5 620 kg (12 365 lb) Tilt dump type rock bucket 4.0 m3 : 4 980 kg (10 960 lb) Tilt dump type general purpose bucket 4.4 m3 : 4 630 kg (10 190 lb)

Lift

Wire rope 18 mmø × 3 000 mm

Detail U

Chain block (for 6 tonne load): 3

Lift

Wire ropes: 3 pcs. 18 mmø × 10 000 mm (L) : 1 pc. (0.7 inø) (390 in L) 18 mmø × 3 000 mm (L) : 2 pcs. (0.7 inø) (117 in L) Shackle (for 6 tonne load):

Shackle

Fig. 63

2 pcs. 1 pc.

Lift the bucket, keeping pin holes a and b level.

Note:

Fig. 64

Level the bucket by adjusting the preset chain blocks.

CAUTION: Never allow anybody to stand directly beneath the lifted bucket.

Position the arm end around 1 100 ~ 1 200 mm (43 ~ 47 in) above the ground.

1 100 mm ~ 1 200 mm (43 in) (47 in) Fig. 65 Lift Move

Moving the bucket to the arm 1

Lift the bucket to a height such that pin holes d in the arm end are level with pin holes c in the bucket. Move the bucket to pin holes d .

d Fig. 66

160

Hold

Installing the bucket 1

Align pin holes a and b in preparation for inserting the pins.

a b

Fig. 67

Insert the pins.

Note: Apply grease to the pins before insertion.

Spring washer

Install the stoppers using bolts and spring washers. Bolt

Note: Apply lubricant to the bolts before installation.

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Stopper

Detail V

Fig. 68

Stopper Bolt Spring washer

Fig. 69

Set O-rings 17 and rings 18 in the groove between the bucket and the arm, as indicated in Fig. 70.

Detail W O-ring 17

Arm

Ring 18 Bucket

Fig. 70

161

Lift

Connecting the bucket link 1

Lower the bucket to the ground, and use a wire rope to lift bucket link a up toward pin hole b .

Wire rope: 10 mmø × 3 000 mm (L) : 1 pc. (0.4 inø) (117 in L) a b

Fig. 71

Hold

Adjust the position of the bucket link with the wire rope and by operating the tilt cylinder, such that hole a in the bucket link is aligned with the bucket pin hole b .

Tilt cylinder Fig. 72

Insert the pins Hold

Note: Grease the pins before insertion.

To prevent the pins from becoming removed, install stoppers over the pin ends using bolts and spring washers. Bolt

Tightening torque: 40 kgf·m (390 N·m/290 lbf·ft)

Stopper Spring washer

Note:

Apply lubricant to the bolts before installation.

Fig. 73

Detail X

Bolt Spring washer Pin

162

Stopper

Fig. 74

Step 15 Installing the bucket open/close hoses

Stop the engine and move each operation lever back and forward, left and right a few times to release any residual pressure.

Install bucket open/close hoses. 1

Detail Y

Remove the caps from the hose ends.

CAUTION: In removing the caps, slowly loosen the tightening bolt and remove the cap only after confirming that all pressure has been released. 2

Connect the 2 bucket open/close hoses 16 .

Tightening torque: 14 kgf·m (140 N·m/100 lbf·ft)

Notes: i) ii) iii) iv) v)

When connecting hoses, do not twist them, or their service life will be shortened. Connect the hoses so as not to make contact with other parts. Make sure that there is no dust sticking to the seat faces of the hoses. Pay attention not to damage the joining surfaces of the hoses. Use O-rings 15 (P/No. 4508805) to install the hoses. Apply a thin layer of sealant #98D to the O-rings before installation.

After connecting the hoses, clean away any residue oil.

Close the air release cock on the hydraulic tank.

Bucket open/close hose 16

Fig. 75

163

Detail Z

Step 16 Fitting the grease hoses

Connect the grease hose to the arm end boss 1

Grease hose

Attach the grease hose as indicated in Fig. 76.

Tightening torque:

6 kgfÂˇm (60 NÂˇm/45 lbfÂˇft)

Notes: i)

Make sure not to twist the hose during installation as doing so can shorten its service life. ii) Install the hose such that it does not contact other parts. iii) Check that the hose mating face is free of dust and contaminants. iv) Make sure not to damage the hose mating face during installation. 2

164

Connect the grease hose for the opposite side in the same manner.

After connecting the grease hoses, clean away any residue grease.

Fig. 76

Step 17

Reinstall the handrail and adjusting the rear view mirror

Reinstalling the removed handrail Reinstall the handrail a removed on page 73 of the base machine assembly instructions. Tightening torque:

9 kgf·m (90 N·m/65 lbf·ft)

Notes: i)

Apply lubricant to the threads of the mounting bolts. ii) Hand screw in all bolts first, before tightening to the specified torque.

Fig. 77

Rear view mirror

Adjusting the rear view mirror Adjust the rear view mirror Check that the operator gets a clear view of the rear of the machine from the operator’s seat. Tightening torque:

1.0 kgf·m (10 N·m/7.2 lbf·ft)

Fig. 78

Step 18 Installing the lamp 1

Put bracket-fitted lamps 10 on the right and left side of the boom.

Tightening torque:

Detail A 10

5 kgf·m (50 N·m/35 lbf·ft) 10

Connect the electric wire couplers a and b . b

Note:

Before connecting the electric wires, remove the anti-corrosive and any rust from the couplers. Fig. 79

165

Step 19

Detail B

Greasing (3)

The machine is provided with a pneumatically operated grease lubricator connected to the hose reel and a grease gun.

Operation procedure: (1) Connect air supply hose to lubricator pump a . (2) Pull out the grease hose from hose reel c while holding grease gun b . (3) Stop pulling out when the reel clicks and desired hose length is obtained; the hose will be locked automatically. (4) Connect grease gun b to the desired grease fitting and pull the gun lever; grease will be supplied automatically by air pressure.

IMPORTANT: c

Run the engine at medium speed or more when supplying grease using the lubricator.

Start the engine.

Supply grease to 6 points as shown in Figs. 81 and 82.

Fig. 80

Notes: i)

Fig. 81

Detail C

Fig. 82

166

Supply grease to 16 points as shown in Figs. 84 and 85. Cap Head

Note: Bucket and Link Pins Each grease fitting is provided with a protective cap. Remove cap as shown below before greasing. Removing/installing procedure: Insert a screw driver into the cap cavity along the Grease arrow "a" direction, and scoop out the cap by Fitting applying force in the arrow "b" direction. Cap When installing, push the cap by hand in the arrow Pin "c" direction until it bottoms or tap using screw driver grip.

Cavity Screw Driver Fig. 83

Detail D

Front Joint Pins (Loading Shovel)

Dump Cylinder Bottom Pin

Dump Cylinder Rod Pin Bucket Joint Pin

Link and Arm Joint Pin

Add grease to all grease fittings This machine employs a block greasing system so that pins located in high places are greased 1

Bucket and Link Pins

Bucket and Link Joint Pin

Bucket Cylinder Bottom Pin Link Joint Pin

Fig. 84

Fig. 85

167

Lubrication method (1) Turn power switch d ON to activate the pump. Grease is sucked up and supplied to high-pressure grease gun b .

d e

Fig. 86

g f b

Fig. 87

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.

h Fig. 88

168

Step 20 Checks

ďź&#x160;

Checking for hose interference Check that, when the boom is maximally raised and lowered, the hoses between the base machine and boom do not contact the central cover on the base machine or other peripheral devices. If there is hose interference, adjust the connection of affected hoses to the control valve.

Problem area

CAUTION: When operating the boom, ensure that no-one other than the operator is in, on, or in the close vicinity of the machine.

Fig. 89

169

8-3 Bleeding the cylinders and checking the hydraulic system Step 1 Boom raise

Bleeding the hydraulic cylinders

Bucket tilt-in

Arm extend

Start the engine.

CAUTION: Make sure that nobody other than the operator is in or on the hydraulic excavator.

Boom Arm retract lower Bucket tilt-out Fig. 1

2 3 4

Note: The engine speed should be kept as low as possible.

Procedure

Action Start the engine.

Note: Run the engine at low speed. Move each cylinder back and forth five times.

Notes: i)

Hold the cylinder at the stroke end for a minute to apply relief pressure and bleed the air from the cylinder. Repeat the procedure twice. Stop the engine.

Bleeding Locations & Cylinder Positions for Bleeding Air

170

(Refer to next page)

Step 2 Bleeding locations

CAUTION: Take all reasonable precautions as this work is to be conducted high above the ground.

Set the front-end attachment on the ground as illustrated below (Fig. 2).

Stop the engine.

CAUTION: Take care to prevent anybody from starting the engine during the work. 3

rod

Level cylinder bottom Arm cylinder bottom

Tilt cylinder rod

Boom cylinder bottom

Tilt cylinder bottom

Arm cylinder rod

Fig. 2

Detail A

Level check

Fig. 3

Fig. 4

171

8-4 Adjusting the track link tension

Adjusting the track link tension 1

90° ~ 110°

Wooden blocks: 2 pcs. 1 200 mm (L) × 800 mm (W) × 1 000 mm (H) (47 in) (31 in) (39 in) 3

Fig. 1

Rotate the uplifted track link forwards through 2 turns, and then backwards through 2 turns.

Wooden block

Detail A

Note: Remove any rocks and other debris caught in the sprockets. (Length L) Standard tension

460 ~ 510 mm (18 ~ 20 in)

To loosen the track link tension, slowly loosen valve a (24mm hex) to release excess grease. 1 to 1.5 turns of the valve should be sufficient. If grease does not escape at a constant rate, slightly

Fig. 2

Detail B

rotate the uplifted track link. Tighten valve a on completion of adjusting the track link tension. Tightening torque: 15 kgf·m (150 N·m/110 lbf·ft)

Detail C

Adjusting the track link tension

a b

172

Fig. 3

Grease outlet

Fig. 4

Detail D Loosen the Track b

IMPORTANT: When gravel or mud is packed between sprockets and track links, remove it before loosening.

To loosen the track, slowly turn valve a counterclockwise using long socket 24; grease will escape from the grease outlet.

Between 1 to 1.5 turns of valve a is sufficient to loosen the track.

If grease does not drain smoothly, slowly rotate the raised track.

Fig. 5

Grease outlet

When the proper track sag is obtained, turn valve a clockwise and tighten to 15 kgf·m (150 N·m/110 lbf·ft).

Fig. 6

Detail E Tighten the Track

CAUTION: It is abnormal if the track to remains tight after turning valve a counterclockwise or if the track is still loose after charging grease to fitting b . 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 b and add grease until the sag is within specifications.

Fig. 7

173

8-5 Final trial operation check Step 1

Detail A

After check

After connecting all the hoses, check that no hose hits against other hose or parts.

Adjust the track link tension to an appropriate figure. (See pages 172 and 173, "Adjustment of track link tension.")

Check all functions of the machine. (See "Checks after completing the assembly.")

Recheck the oil level in the hydraulic tank. If the oil is low, refill the tank through the oil filler port.

CAUTION: Before starting the excavator, make sure there is no person other than the operator in or on the machine. Fig. 1

Note: After the above procedures are completed, work at 60% to 70% power for the first 50 hours of operation, and then begin full-power operation.

Fig. 2

Step 2 Final checks for the loader front-end

Thoroughly clean any oil from the machine with waste cloths.

On full completion of the backhoe assembly, recheck that all bolts are tightened to the specified torque.

Detail B

Fig. 3

174

8-6 Loader lubrication

Lubrication Lubricating points and grease types After assembling the loader front-end, lubricate the points illustrated in Fig. 1.

b b

Select an appropriate grease type according to the following table.

Brand Name of Recommended Grease Application Air Temp.

Manufacturer

Fig. 1

Bucket, Arm and Boom, Swing Gear, Swing Bearing, etc. − 20 to 40°C (− 4 to 104°F)

Hitachi Genuine

Doubrex SEP Grease

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 EP Grease

Locations requiring lubrication

Note: On shipment from the factory, the machine is filled with the lubricant marked .

No.

Front joint pins (around bucket)

Front joint pins (other than around bucket)

175

Lubrication method Lubrication with the lubricator The machine is fitted with a lubricator and hose reel, which can be used for easy-operation pneumatic lubrication.

CAUTION:

a d

Lubrication of the top of the boom and arm is performed at height. Take appropriate measures to avoid falling from the machine.

Note:

Set the engine to run at medium idle or higher when using the lubricator.

Lubricator Operation 1

Turn power switch ON to activate the pump. Grease is sucked up and supplied to highpressure grease gun .

Fig. 2

CAUTION: When detaching hydro-chuck g from grease nipple h , grease nipple h tip may break unless special care is taken, as follows: Âˇ Tilt nozzle f a little so as to release the connecting pressure applied to hydro-chuck g . Âˇ Slowly detach hydro-chuck g from nipple h . 5

g f b

Note:

Fig. 3

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. h Fig. 4

176

NOTES

177

NOTES

178

9. Extending and retracting the side frames 1

Precautions when extending or retracting the side frames Accumulation of dust or debris on the mounting faces of the track frames and side frames can lead to the loosening of bolts. Thoroughly clean all affected portions of the frames before performing any work.

Note: The side frames should be retracted only during transportation (when loading onto or off a truck and when operating the machine during loading /unloading). Under no circumstances should the side frames be retracted during digging work on when driving the machine. Operation of the machine with the side frames retracted (or one side frame retracted) will lead to machine instability and potentially cause damage to the track and side frame bolts.

179

PROCEDURE OF EXTENDING SIDE FRAME [Necessary Equipment] (1) Slinging Rope (20 mm dia. x 8 m, 6 x 37 Ordinary Z lay Class A, Applicable Max. Load: 3 tons) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6 Used Before slinging, make sure no broken wire strands and/or kinks exist. (2) Lever Block (JIS B8819 equivalent to L3.2T) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 Used Check that there is no damage on the lever block. (3) Power Boost Wrench (including accessories), width across flats of the torque wrench: 55 mm (4) Air Compressor (slide surface cleaning) (5) Soft Protectors

CAUTION: i)

Group work is required. Before starting work, coordinate work procedures with co-workers. ii) Damage to the lever block and/or wire rope may result along with severe personal injury. When extending the side fame using the front attachment, do not allow any personnel to enter the vicinity of the machine.

Fig. 1

CAUTION: Do not loosen side frame guide bolts 9 .

IMPORTANT: When the machine is shipped from the factory, all side frame tightening bolts are not installed. Therefore, unbolted screw holes on the side frame are coated with rust-inhibitor so that they may be clogged with dust or soil. Before installing the tightening bolts, clean the thread surface thoroughly. If the bolts are difficult to tighten, tap the screw holes again. Tap: M36, Pitch: 3 mm

IMPORTANT: Before working, completely clean the side frame slide surfaces using compressed air. If mud and/or gravel is stuck on the contact areas of track frame 2 and side frame 3 , the work may be interrupted and loose mounting bolts 1 may result. 1. 2.

180

Remove side frame mounting bolts 1 (10 used, 5 bolts in two places) from the extending side frame. Rotate the upper structure to the side of the extending side frame until the front attachment faces the side frame perpendicularly. Set the arm and boom angle between 90° to 110°. Then, lower the bucket bottom to the ground.

90° ~ 110°

Fig. 2

Wind two wire ropes 4 around the front and rear sections (one wire rope on each section) of the side frame. Connect lever block 5 to the ends of each wire rope. Attach soft protectors 6 between the side frame 3 corners and wire ropes 4 to prevent damage to side frame 3 and wire ropes 4 . Pass two wire ropes 8 round the arm near the bracket of bucket 7 . Connect each rope end to lever block 5 . Then, slowly extend the front attachment so that the slack of wire ropes is removed. Put soft protector 6 between the bucket bracket corner and wire rope to prevent damage to wire ropes. Retracting side frame (Track gauge) Turn the boom mode switch OFF so that the machine can be raised off the ground with front attachment. While lowering the boom, raise the extending side frame approx. 50 mm above the ground. If the side frame is raised too much, extending force increases. Operate lever blocks 5 so that the rear (travel device side) and front (front idler side) of the side frame is equally extended until side frame guide 9 comes in contact with the track frame stopper.

4 3 6

Fig. 3

6 7 8

Fig. 4

CAUTION: When the lever block becomes inoperable, it is because too much resistance exists against the extending force. Avoid working by force. Otherwise, lever block and/or wire rope may be damaged and/or fly away, possibly resulting in severe personal injury. Stop the work and check if the front and rear of the side frame are equally extended or if the side frame is raised to the proper height. Take corrective measures as necessary.

5 6 7 8 Fig. 5

CAUTION: After raising the side frame above the ground, never operate the arm to extend the side frame. If the arm is operated, the wire ropes are pulled with excessive tension force. Damage to the lever block or wire rope may result, possibly causing severe personal injury.

When side frame guide 9 comes in contact with the track frame stopper, install side frame tightening bolts 1 (22 used) (11 used in two places) and tighten temporarily by hand. In case it is difficult to tighten with hand, bolt and screw hole centers may not be correctly aligned. Re-align bolt and screw hole centers by operating the lever blocks.

2 1

9 Fig. 6

181

CAUTION: Be sure to slowly operate the boom. If quickly operated, the lever block and/or wire rope may be damaged and/or fly away, possibly causing severe personal injury. Stay away from the machine when operating the boom. 10. Slightly slacken wire rope tension by operating lever blocks 5 and raise the boom to slightly lower the track frame. Don't slacken wire rope tension excessively. Also, take care not to lower the track frame excessively. If excessively slackened or lowered, side frame 3 will retract making retightening (by hand) of bolts difficult. 11. After slightly lowering track frame 2 , re-tighten bolts 1 by hand. 12. Repeat steps 10 and 11 three to four times until the track frame is completely lowered to the ground. 13. Slacken the lever blocks. Remove the lever blocks and wire ropes. 14. Tighten bolts 1 with the power boost wrench and torque wrench to specification. Tightening torque: 285 kgf·m (2 800 N·m/2 065 lbf·ft)

Fig. 7

3 Longer bolt

IMPORTANT:

Be sure to apply a film of lubricant to the bolt threads. 15. Extend the side frame on the opposite side in the same procedure. 16. When the loader front attachment is installed, hook the wire ropes to the teeth in the right and left edges.

Longer bolt

Fig. 8

Hook the wire rope to the tooth

90 to 110°

Wire rope Raise the track slightly off the ground

Fig. 9

Torque Model

182

Bolt Size

Width Across Flats mm (in) kgf·m

N·m

lb·fb

ZX800

M36-Pitch 3

55 (2.1)

285

2800

2065

ZX850H

M36-Pitch 3

55 (2.1)

285

2800

2065

RETRACTING THE SIDE FRAME 4

CAUTION: Do not loosen side frame guide, bolts 2

IMPORTANT: Remove and clean mud and gravel from contact area of track frame 3 and side frame 4 using compressed air. Required Tools: Power Boost Wrench (including accessories) Torque Wrench (width across flats: 55 mm) Air Compressor (slide surface cleaning)

2 1. 2.

Remove eighteen mounting bolts 1 (11 used for each side) from the retracting side frames. Retracting side frame (Track gauge) Turn the boom mode switch OFF so that the machine can be raised off the ground with front attachment. Raise track 6 to be retracted using the front attachment, as illustrated. Slowly rotate raised track 6 back and forth. The side frame will be retracted with its own weight and stop when it comes into contact with guide 2 .

Fig. 10

90° ~ 110°

approximately 15° Fig. 11

IMPORTANT: Maintain a 90° to 110° angle; never make an acute angle between the boom and the arm.

If side frame 4 does not retract completely, lower the undercarriage and turn the upperstructure 180°. Raise the opposite side track about 15° from the ground using the front attachment. Slowly push the arm out, to retract side frame 4 .

IMPORTANT: Do not raise track 6 excessively high or operate the arm-control lever abruptly. Damage to the track frame may result.

Slowly lower track 6 to the ground. Tighten six mounting bolts 5 (5 used for each side) to the specification. Tightening torque:

Fig. 12

285 kgf·m (2 800 N·m/2 065 lbf·ft)

Retract the opposite side, following procedures 1 to 4 above.

183

EXTENDING SIDE FRAME [Necessary Equipment] (1) Slinging Rope (20 mm dia. x 8 m, 6 x 37 Ordinary Z lay Class A, Applicable Max. Load: 3 tons) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6 Used Before slinging, make sure no broken wire strands and/or kinks exist. (2) Lever Block (JIS B8819 equivalent to L3.2T) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 Used Check that there is no damage on the lever block. (3) Power Boost Wrench (including accessories), width across flats of the torque wrench: 55 mm (4) Air Compressor (slide surface cleaning) (5) Soft Protectors

CAUTION: i)

Group work is required. Before starting work, coordinate work procedures with co-workers. ii) Damage to the lever block and/or wire rope may result along with severe personal injury. When extending the side frame using the front attachment, do not allow any personnel to enter the vicinity of the machine.

Fig. 13

CAUTION: Do not loosen side frame guide bolts 9 .

184

Remove side frame mounting bolts 1 (10 used, 5 bolts in two places) from the extending side frame. Rotate the upperstructure to the side of the extending side frame until the front attachment faces the side frame perpendicularly. Set the arm and boom angle between 90° to 110°. Then, lower the bucket bottom to the ground.

Fig. 14

Wing two wire ropes 4 around the front and rear sections (one wire rope on each section) of the side frame. Connect lever block 5 to the ends of each wire rope. Attach soft protectors 6 between the side frame 3 corners and wire ropes 4 to prevent damage to side frame 3 and wire ropes 4 . Pass two wire ropes 8 round the arm near the bracket of bucket 7 . Connect each rope end to lever block 5 . Then, slowly extend the front attachment so that the slack of wire ropes is removed. Put soft protector 6 between the bucket bracket corner and wire rope to prevent damage to wire ropes. Retracting side frame (Track gauge) Turn the boom mode switch OFF so that the machine can be raised off the ground with front attachment. While lowering the boom, raise the extending side frame approx. 50 mm above the ground. If the side frame is raised too much, extending force increases. Operate lever blocks 5 so that the rear (travel device side) and front (front idler side) of the side frame is equally extended until side frame guide 9 comes in contact with the track frame stopper.

4 3 6

Fig. 15

6 7 8

Fig. 16

CAUTION: When the lever block becomes inoperable, it is because too much resistance exists against the extending force. Avoid working by force. Otherwise, lever block and/or wire rope may be damaged and/or fly away possibly resulting in severe personal injury. Stop the work and check if the front and rear of the side frame are equally extended or if the side frame is raised to the proper height. Take corrective measures as necessary.

5 5 7 8 Fig. 17

2 1

9 Fig. 18

185

Fig. 19

3 Longer bolt

IMPORTANT:

Longer bolt

Fig. 20

Hook the wire rope to the tooth

90 to 110°

Wire rope Raise the track slightly off the ground

Fig. 21

Torque Model

186

Bolt Size

Width Across Flats mm (in) kgf·m

N·m

lb·fb

ZX800

M36-Pitch 3

55 (2.1)

285

2800

2065

ZX850H

M36-Pitch 3

55 (2.1)

285

2800

2065

Machine disassembly It is necessary to disassemble the machine for transportation. The disassembly procedure is the reverse of the assembly procedure. Refer to the assembly instructions.

Long-distance travel The machine has a maximum travel speed of 4.6km/h. Drive the machine over level surfaces as much as possible. Avoid riverbeds or any other areas covered with rounded stones, as travelling over such surfaces can bend the track shoes. For long-distance heavy transportation, pre-inspect the machine, and determine the quantity of traffic along the intended route, the quality of the road surface and the width of the road. If you are to cross any bridges, check for restrictions on heavy vehicles, and reinforce the bridge if it is not strong enough to hold the machine. Take due care when crossing railway lines, and lay planks or equivalent over the rails to avoid riding up directly onto the rails.

Notes: i) Pre-inspect the undercarriage to avoid damage during long-distance travel. ii) Use protective fittings on plates to avoid damaging the road surface. Be particularly careful when steering over sealed road surfaces in the summer. Take care to avoid hitting overhead wires. iii) If necessary, position a person in front of the machine to direct it. iv) Cross rivers carefully, checking the river bottom regularly with the bucket. Make sure not to exceed the maximum water depth.

187

NOTES

188

ZX800/ZX850H Assembly Manual

CHECKING

CHECKS & PERFORMANCE STANDARDS

10. Checks after completing the assembly 1

After assembly, clean and wipe each part thoroughly with a rag.

Inspect the excavator before starting the engine.

CYLINDERS AND HYDRAULIC LINES Check for oil leaks.

PEDALS AND LEVERS Check for freedom of movement. RESERVOIR Check coolant level.

PINS AND BOLTS Check for looseness or absence.

RADIATOR Clean fins. OIL COOLER Clean fins.

OPERATOR'S CAB Clean.

HYDRAULIC TANK Check oil level. FINAL DRIVE Check oil level.

ENGINE Check oil level.

Fig. 1

Checks after completing of assembly 1

2 3 4

6 7 8

Electrical system Check for worn or frayed wires and loose connections. Boom, bucket, arm, frame, and tracks Check for deformed, broken, or missing parts. Hardware Check for loose or missing parts. Hydraulic system Check for leaks, kinked hoses and lines, or hoses that rub against each other or other parts. Lubrication Check the lubrication points listed in the Operation Manual. Protective devices Check guards and fenders. Check that the parts are correctly reassembled. Apply touch-up paint if necessary, after completing assembly.

Fig. 2

191

Check the instruments immediately after starting the engine. 1

IMPORTANT: If a gauge does not operate correctly as shown below, STOP THE ENGINE IMMEDIATELY and take all necessary measures. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

22 21

Coolant Temperature Gauge Fuel Gauge Display Selection Switch Set Switch Work Mode Switch Fuel Level Indicator Air Filter Restriction Indicator Alternator Indicator Coolant Level Indicator Quick-Idle Indicator Precision Mode Indicator Auto-Lubrication Indicator Engine Oil Level Indicator Engine Oil Pressure Indicator Preheat Indicator Overheat Indicator General Purpose Mode Indicator Trench Digging Mode Indicator Attachment Mode Indicator Liquid Crystal Display (LCD) (Hour Meter, etc.) Auto-Idle Indicator Auto-Acceleration Indicator

20 19 18

17 4

5 16

9 12 11

10 Fig. 3

Measurement of engine revolutions Determination

Item

Engine revolutions (rpm)

Low-speed idling

900 ± 100

Quick idling

900 ± 100

Auto idling High-speed idling

192

Standard for new machine

1 250 ± 100 HP Mode 1 850 ± 100 E Mode 1 820 ± 100

Fig. 4

11. Checking machine performance The figures and tolerances listed on the next page onward are for new machines. The measurements should be performed under the following conditions: · Engine speed: Maximum · Hydraulic oil temperature: 50° ± 5°C · Site: Firm level ground

Note: Measure each actuator speed after sufficiently operating the machine.

193

TRACK LINE OFF AMOUNT WHEN TRAVELING Note: Perform inspection over a broad, flat workspace. If such a space is not available, the "TRACK LINK SPEED FOR 3 FULL TURNS" check should be used as an indication of track line off.

Preparation

Fig. 1

Fig. 2

Measurement 1 2

Move both travel levers to the stroke end. Measure the largest deviation distance "a" between the machine trace and a line drawn between the start and stop points of the machine, as shown the Fig. 3.

a m 20 . 6 ft) (65

Bring machine to rest over 7~9m (25 ~ 30 ft) Fig. 3

Determination Front

Unit: mm (in) Item Deviation distance

Standard

FORWARD

Less than 200 (7.8) REVERSE

194

TRACK LINK SPEED FOR 3 FULL TURNS

Preparation

90° ~ 110° 90° ~ 110° Fig. 4

1 2

Fig. 5

Mark any one of the track shoes on the side where this test is to be performed. Jack up the track to be tested. (Figs. 4 and 5)

Measurement Front

1 2 3

Accelerate the engine to maximum speed. Measure the time required to make three full turns. Repeat this test for both tracks in the forward and reverse directions.

FORWARD

REVERSE

Determination Unit: sec. Item

Standard

Forward speed

Track link speed/ 3 rev. (High)

32.2±2.0

Reverse speed

Track link speed/ 3 rev. (High)

46.1±2.0

195

SWING SPEED FOR 3 FULL TURNS

Preparation

Fig. 6

Fig. 7

Measurement 1 2

Set the swing control lever to full stroke. Measure the time required for three full turns at a constant speed.

Front

Three full turns

SWING RIGHT

SWING LEFT

Fig. 8

Determination

Unit: sec. Item

196

Standard

Swing speed/3 rev.

22.0±1.5

Swing speed/3 rev.

22.0±1.5

AMOUNT OF COASTING DURING SWING

Preparation

Fig. 9

1 2 3 4

Fig. 10

The arm cylinder should be fully extended. The bucket cylinder should be fully retracted. Place an aligning mark between the swing frame and the track frame. Swing the superstructure so that the swing frame is at 90° to the track frame.

MEASURE THE DIFFERENCE

MARK ON THE FRAME MARK ON THE SWING BEARING

Measurement 1 2 3

Set the swing control lever to full stroke. After swinging 180°, return the lever to the neutral position. Measure the amount of coasting.

Amount of coasting Swing stop

180° swing

Fig. 11

Determination Front

Unit: mm (in) Standard

Item

SWING RIGHT Amount of coasting

Less than 1 198 (46.7)

SWING LEFT

197

CYLINDER SPEED (Loader front)

Action

Fig. 12

Fig. 13

Fig. 14

Fig. 15

Repeat the time measurement at least 3 times for each item and record the average time.

Note: For machines with a bucket tilt controller (an option), be sure to turn the bucket control switch to OFF when measuring the boom raise speed.

Determination Unit: sec. Item Boom cylinder

Loader Front Raise

5.2±0.4

Lower

4.5±0.4

Retract

2.3±0.4

Extend

3.1±0.4

Tilt-in

3.8±0.4

Tilt-out

3.4±0.4

Open

1.2±0.3

Fig. 12

Fig. 13

Arm cylinder

Bucket

198

Fig. 14

Fig. 15

CYLINDER SPEED (Backhoe front)

Action

Fig. 16

Fig. 17

Repeat the time measurement at least 3 times for each item and record the average time.

Fig. 18

Determination Unit: sec. Backhoe Front

Item

Boom cylinder

ZX800

ZX850H

Raise

4.0±0.3

4.4±0.4

Lower

3.1±0.3

2.9±0.4

Roll-in

4.3±0.3

4.6±0.4

Roll-out

3.2±0.3

3.7±0.4

Roll-in

2.7±0.3

2.7±0.4

Roll-out

2.7±0.3

2.8±0.4

Fig. 16

Arm cylinder

Fig. 17

Bucket cylinder

Fig. 18

199

AMOUNT OF HYDRAULIC CYLINDER CREEP

Preparation With a full load in the bucket, set the front-end attachment as shown above.

Application 0.0 m3 (0.00 Cu. YD)-PCSA heaped bucket

2 000 mm (79 in) Fig. 19

Application 0.00 m (00' 0") BOOM 0.0 m (00' 00") ARM 0.0 m3 (0.00 Cu. YD) Bucket (PCSA)-Bucket weight: 0 000 kg 1 200 mm (47 in) Fig. 20

Measurement Mark Mark

1 2

Stop the engine. Measure the amount of creep over 5 minutes.

Determination

Fig. 21

Unit: mm (in)

200

Item

Loader Front

Backhoe Front

Boom cylinder, mm/5min

Less than 30 (1.17)

Less than 21 (0.81)

Arm cylinder, mm/5min

Less than 20 (0.78)

Less than 16 (0.62)

Bucket cylinder, mm/5min Less than 20 (0.78)

Less than 15 (0.58)

Make marks with touch-up paint if necessary.

Aâ&#x2C6;&#x2019;B = Natural lowering

NOTES

201

NOTES

202

12. Appendix (Lifting Diagrams) Superstructure lifting jug 12-1 Assembly Instructions Appendix (Right bracket)

8089397

12-2 Assembly Instructions Appendix (Left bracket)

8089392

12-3 Superstructure lifting jig

9217176

203

Miscellaneous Diagrams 12-1 ZX800/ZX850H Assembly Instructions Appendix (Right bracket)

ø40 Gas cut

DWG. No.

8089397 205

12-2 ZX800/ZX850H Assembly Instructions Appendix (Left bracket)

ø40 Gas cut

DWG. No.

8089392 207

12-3 Superstructure lifting jig

Tightening torque: 55 kgf·m (540 N·m/400 lbf·ft)

DWG. No.

9217176 209

Head Office:

5-1, Koraku 2-chome, Bunkyo-ku, Tokyo 112-0004 Japan

Telephone:

Tokyo (03) 3830-8050

Facsimile:

Tokyo (03) 3830-8202

Printed in Japan KG