Ko 282 00

KO-282-00
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.
i
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)
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)
LOADER FRONT
iv
Weight: ZX800 Weight: ZX850H

4.0 m3 (5.23 yd3) 4.4 m3 (5.75 yd3) 3.6 m3 (4.71 yd3) 4.0 m3 (5.23 yd3)
Standard Bottom Dump Bucket Standard Tilt Dump Bucket Bottom Dump Lock Bucket Tilt Dump Lock Bucket
77 700 kg (171 300 lb) 76 700 kg (169 100 lb) 78 400 kg (172 800 lb) 77 300 kg (170 400 lb)
LOADER FRONT
v
Weight: ZX800 Weight: ZX850H

4.0 m3 (5.23 yd3) 4.4 m3 (5.75 yd3) 3.6 m3 (4.71 yd3) 4.0 m3 (5.23 yd3)
Standard Bottom Dump Bucket Standard Tilt Dump Bucket Bottom Dump Lock Bucket Tilt Dump Lock Bucket
77 700 kg (171 300 lb) 76 700 kg (169 100 lb) 78 400 kg (172 800 lb) 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
2. Work Plan and Preparations…………………………………………………………………………………………27
2-1. Work Plan (Backhoe Front) ……………………………………………………………………………………27
2-2. Work Plan (Loader Front) ………………………………………………………………………………………28
2-3. Transportation……………………………………………………………………………………………………29
3. Parts check ……………………………………………………………………………………………………………47
3-1. Check ……………………………………………………………………………………………………………47
4. Preparations ……………………………………………………………………………………………………………48
4-1. Preparations (Backhoe front) …………………………………………………………………………………48
4-2. Preparations (Loader front) ……………………………………………………………………………………49
5. Machines, apparatuses, tools, and materials necessary for assembly ……………………………………50
6. 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
7. 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
8. 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
9. 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
vi
1. Precautions
1-1 Safety precautions for servicemen
1 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
2 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.
1
3 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.
4 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
5 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
2
6 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 Fig. 1-6
• Respirator or filter mask.
7 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
8 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
Fig. 1-8
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.
3
9 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
10 SUPPORT RAISED EQUIPMENT

Never work under or near a raised bucket. Lower the
bucket to the ground or onto secure blocks.
Fig. 1-10
11 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, Fig. 1-11

and handrails when getting off the machine.
4
12 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, non-
flammable solvents.
Fig. 1-12
13 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 16°C (60.8°F).
Disconnect the negative ground cable before working

on the electrical system or making major repairs.
Fig. 1-13-1
Fig. 1-13-2
5
14 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 high-
pressure fluids. Wear a face shield or safety goggles
for eye protection.
• If an accident occurs, see a doctor familiar with this Fig. 1-14-1

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. 1-14-3 Fig. 1-14-4
15 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
6
16 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
17 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
18 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
7
19 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.
Fig. 1-19-1
• 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.
If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
Boom
If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support
Arm
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

90 to
as necessary. Refer to the relevant section of the 110°
Operation Manual.
Keep all parts in good condition and properly installed. Fig. 1-19-2
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.
8
20 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
21 REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.
Remove paint before welding or heating:
1 If you sand or grind paint, avoid breathing the

dust. Wear an approved respirator.
2 If you use solvent or paint stripper, remove

stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
Fig. 1-21
to disperse at least 15 minutes before welding or
heating.
22 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
9
23 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 Fig. 1-23
gradually loosen the AIR RELEASE PLUG to release
pressure.
24 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
Fig. 1-24-1
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.
Fig. 1-24-2
Wait for the oil and components to cool before
starting any maintenance or inspection work.
25 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
10
26 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 Fig. 1-26
into any water source.
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.
27 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.
28 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
11
29 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
2 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
3 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
Fig. 1-31
it is not possible to change 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. 1-32
2
12
30 COMMUNICATION
1 When slinging work is performed on heavy loads,
a predetermined hand signalling method should
be used for trouble-free communication.
2 In order to facilitate remote teamwork during

assembly, workers should wear headsets for
reliable communication.
Fig. 1-33
31 COMPONENT NAMES 1 Bucket 8 Hydraulic Oil Tank

2 Bucket Cylinder 9 Engine
3 Arm 10 Counterweight
4 Arm Cylinder 11 Travel Device
5 Boom Cylinder 12 Track
3 4 6 Boom 13 Front ldler
7 Fuel Tank 14 Cab
2
7
1 8
9
14
13
10
12
Fig. 1-34
11
13
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.
1 METHOD OF USE 4. Input direction selection on the

ratchet handle.
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.
Changeover
Select the input direction by setting clutch
Fig. 1-35
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.
bolt. Elastic deformation (force)
2
Depending upon the wrench type the reaction lever usually acts
between the wrench and bolt can
radially. Due to the large reaction force applied to the reaction lever, the 1
make it difficult to remove the
reaction lever should be positioned so that it is both secure and stable.
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 L
8-150P 110
8-300P 130
12-450P 145
12-600P 160
(Unit: mm)
Fig. 1-38
Fig. 1-42
14
2 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.
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. 1-44
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
1
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
2
15
(2548)
5. Power Wrench Input/Output Diagram
Input/Output Diagram (2254)
[Output=input x gear ratio x efficiency]
(1960)
(1666)
Output kgf·m (lbf·ft)

(N.m)
(1372)
(1078)
In selecting a power wrench, give due consideration of the
differences in power performance between the different
(784)
wrench types.
(490)
Input kgf·m
(lbf·ft)
Bolt Power Wrench (N.m) (98) (196) (294) (392) (490) (588) (686) (784) (882)
(6860)
(5880)
Fig. 1-49 (4900)
(3920)
Output kgf·m (lbf·ft)
(N.m)
(2940)
(1960)
Input kgf·m
(lbf·ft)
(N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)
6. Torque Specifications
Bolt Dia Wrench Tightening Torque

No. Descriptions (mm) Side (mm) kgf·m N·m lbf·ft
1 Side frame mounting bolt M36 55 285 2795 2060
2 Counterweight mounting bolt M48 65 350 3430 2530
3 Counterweight lock plate securing bolt M24 36 70 690 510
3
1- 16 -12UNF 36 18 175 130
ORS fittings for hydraulic hoses
4 and piping 7 -12UNF
1- 16 41 21 205 150
5 Front pin retaining bolt (Backhoe) M20 30 40 390 290
M20 30 40 390 290
Front pin retaining bolt
6 (Loading shovel) M16 24 21 205 150
M12 19 9 90 65
16
1-3 Work precautions
1 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
White zinc jelly
proportions.
Spindle oil
In the case that these materials are not available,
make up the lubricant from materials of the same
composition:
1:1
Material Composition
White zinc jelly Composition list given on page 26
Spindle oil Composition list given on page 26
2 Lubricant should be applied to both the bolt and
spacer, in the positions marked ＊ in the diagram
Lubricant
below.
Spacer
Bolt
Fig. 1-50
＊＊＊＊ Base
Face area Face area Thread of the head
Fig. 1-51
2 HANDLING SEALS
High Tack Adhesive/
1 Remove the seal fitted to the ports and pipes of Sealant #98D
hydraulic components just before assembly, to
prevent the ingress of dust.
2 Oil will come out when removing the seals from Fig. 1-52
the hydraulic ports. Collect it with a suitable oil

container.
3 Lightly apply High Tack Adhesive/Sealant #98D to
the O-ring before hose connection.
Note:
Obtain high tack adhesive/sealant #98D through the
manufacturer detailed on page 26.
Fig. 1-53
3 CONNECTING HOSES.
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors.
3 When connecting hoses, do not twist them or their Battery
service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
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.
4 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 Fig. 1-54
work. Remove cables here
17
5 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 Fig. 1-55
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
2 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 Fig. 1-56
and bolted part. (See Fig. 1-55.)

2) Use only genuine Hitachi bolts.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) 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
6 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,
Pin
then regrease them and spray them with Moly
coat.
2 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
Fig. 1-58
absolutely forbidden. Any other unreasonable
force can lead to a pin being misformed and
rendered unusable, and should be avoided.
(Fig. 1-58)
7 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
18
8 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
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. Fitting

2) Thoroughly clean the hose fitting and
adaptor, then connect them, taking care Remove
the plugs
to prevent the ingression of any
contaminants.
Detail B
Fig. 1-61
Step 3 Connect the adaptor and hose fitting. Adaptor
Notes: Fitting
i) 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 Detail C
the seat face of the hoses. Fig. 1-62
iv) Be careful to not damage the joining
surfaces of the hoses.
19
9 Standards for Hydraulic Joint Work
A 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
O-ring Fig. 1-63
2 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
3 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
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly!!
• Use a specified torque wrench!!
Note:
After the work, carry out a check using a white pen!!
20
B 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.)
3 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
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly!!
• 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!!
21
C 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 Hose, flange
2 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. Fig. 1-70
3 Installing the split flange

1) Temporarily install one side of the split flange 2) Confirm the O-ring and set the hose onto the
using the socket bolts. split flange.
Note: Notes:
Using your hands, screw in the bolt to about half its i) Make sure to insert the hose horizontally to the
length!! 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 Fig. 1-72
Split flange Socket bolts
22
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 O-
ring 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

If the bolt has not been
screwed in adequately,
the instability of the hose
seat surface will increase,
causing the O-ring to fall
Fig. 1-73 off
Fig. 1-74
4 Tightening the socket bolt

1) Temporary tightening, hose angle adjustment 2) Tightening the bolts
• Make sure to tighten the bolts in the correct • Tighten the bolts using a crisscross
order to avoid lopsided tightening. sequence in the same way as for temporary
• The bolts should be tightened using a tightening.
crisscross sequence. • Be careful not to tighten the bolts lopsidedly.
• The hose should still have movement even • Be careful not to overtighten the bolts with
after the bolts have been tightened. an impact wrench.
• Adjust the hose angle.
3) Checking the torque
1 4 • Use a torque wrench to check that the bolts
are properly tightened.
• Check the bolts in the same crisscross
Bolt tightening sequence sequence as for tightening.
• After the work, carry out a check using a
white pen.
3 2
Fig. 1-75
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-76 Fig. 1-77
23
10 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 Rubber boots

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.
• 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 Rubber boots
and female terminals. Take care that the rubber boot
Fig. 1-78
is not out of place or pinched during connection.
24
11 ADJUSTING LIFTING ANGLE
Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever
block) connecting the wire ropes, the lifted angle of the
load can easily be adjusted.
Wire rope
L'
Wire rope
L
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
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-80
25
12 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 160°C (320°F)
Density: 0.89 ~ 0.95 g/cm3
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
2 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.)
13 Read the operation manual and this assembly

procedure manual thoroughly to familiarize yourself
with the work procedure.
Fig. 1-81
26
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.
day day
Days
1 2
Fine weather
30 t x 0.5 day
Crane (With operator and assistant)
30 tonnes
2 sets x 0.5 day

Scaffolding
Tool inspection
Unloading
Unpacking major
Preparation Workers
components
Part inspection Supervisor 1

Workers 2
x 1 day
Cleaning parts
Frame assembly
Assembly work
Backhoe front assembly
Counterweight assembly
Bucket assembly
Lubrication
Track link adjustment
Adjustments Operation
Touch-up painting
Final assembly check
27
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.
day day
Days
1 2
Fine weather
30 t x 0.5 day
Crane (With operator and assistant)
30 tonnes
2 sets x 0.5 day

Scaffolding
Tool inspection
Unloading
Unpacking major
Preparation Workers
components
Part inspection Supervisor 1

Workers 2
x 1 day
Cleaning parts
Side frame assembly

Assembly work
Loader front assembly
Counterweight assembly
Bucket assembly
Lubrication
Track link adjustment
Adjustments Operation
Touch-up painting
Final assembly check
28
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.
29
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.
30
TRANSPORTATION
31
TRANSPORTATION
32
TRANSPORTATION
33
TRANSPORTATION
34
TRANSPORTATION
35
TRANSPORTATION
36
TRANSPORTATION
37
TRANSPORTATION
38
TRANSPORTATION
39
TRANSPORTATION
40
TRANSPORTATION
41
TRANSPORTATION
42
TRANSPORTATION
43
1 Transportation (Backhoe front)
F
H
Example : Backhoe Front (Unit: metric tonne)
Base machine A
· Boom B
Side frames F · Arm C Handrails,
fitted · Bucket D Side Counter- Ladders,
· Boom frame F X 2 weight G Steps,
cylinder etc. H
E X2
48-tonne 48t
trailer
25-tonne 25t 25t

trailer
Trailers/trucks
18-tonne 18t
truck
15-tonne 15t
truck
10-tonne 10t
truck
44
2 Transportation (Loader front)
E
G
Example : Loader Front (Unit: metric tonne)
Base machine A
· Boom
Side frames E linkage B Handrails,
fitted · Bucket C Side Counter- Ladders,
· Boom frame E X 2 weight F Steps,
cylinder etc. G
DX 2
48-tonne 48t
trailer
25-tonne 25t 25t

trailer
Trailers/trucks
20-tonne 20t
truck
15-tonne 15t
truck
10-tonne 10t
truck
45
NOTES
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46
3. Parts check
3-1 Check
1 Unpack the major component parts.
2 Check their quantity against that shown on the packing

list.
3 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
47
4. Preparations
4-1 Preparations (Backhoe front)
Work site: Select a flat, firm site.

Work site size: 17 m × 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 Base machine 14 Travel piping covers

2 Boom (with arm cylinder) 15 Track frame mounting bolts
3 Arm (with bucket cylinder and link) 16 Wiper assemblyv
4 Boom cylinder (L) 17 Headlight
5 Boom cylinder (R) 18 Radio antennav
6 Hydraulic hoses (for bucket cylinder) 19 Tool set
7 Hydraulic hoses (for boom cylinder) 20 Spare parts
8 Counterweight 21 Key, O-rings, washers, part list, manual, etc.
9 Side step 22 Backhoe bucket
10 Handrails 23 Side frame (L)
11 Oil tank steps 24 Side frame (R)
12 Track frame steps
13 Exhaust piping
18
17
7 21
6 20
19 14
13
12 16
15 11
10
9
22
2
5
4
1
3
20 24
m
m
17
23 8
48
4-2 Preparations (Loader front)
Work site: Select a flat, firm site.

Work site size: 17 m × 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 Base machine 17 Exhaust piping

2 Loader front assembly 18 Travel piping covers
3 Boom cylinder (L) 19 Track frame mounting bolts
4 Boom cylinder (R) 20 Wiper assembly
5 Hoses between boom and arm 21 Headlight
6 Hoses between arm and bucket 22 Radio antenna
7 Hoses between main frame and boom 2 pcs. 23 Tool set
8 Hoses between main frame and boom 2 pcs. 24 Spare parts
9 Hose clamp between main frame and boom 25 Key, O-rings, washers, part list, manual, etc.
10 Hose clamp between boom and arm 26 Loader bucket
11 Boom cylinder hydraulic hoses 27 Side frame (L)
12 Counterweight 28 Side frame (R)
13 Side step
14 Handrails
15 Oil tank steps
16 Track frame steps (for 650 mm shoes)
8
7 21
6 11 25
5 10 24
9 23
22 18
17 21
16 20
19 15
14
13
26
4
2
3
20 28
m
m
17
12
27
49
5. Machines, apparatuses, tools, and materials necessary for assembly
1 Crane
30 tonne crane × 1
2 Wire ropes
34mmø × 10 000 mm (L) × 2
(1.3 inø) (390 in L)
34mmø × 3 000 mm (L) × 4
(1.3 inø) (117 in L)
26 mmø × 10 000 mm (L) × 1
(1.0 inø) (390 in L)
26 mmø × 8 000 mm (L) × 2
(1.0 inø) (312 in L)
26 mmø × 3 000 mm (L) × 2
(1.0 inø) (117 in L)
24 mmø × 10 000 mm (L) × 2
(0.9 inø) (390 in L)
18 mmø × 10 000 mm (L) × 1
(0.7 inø) (390 in L)
18 mmø × 3 000 mm (L) × 2
(0.7 inø) (117 in L)
14 mmø × 10 000 mm (L) × 2
(0.55 inø) (390 in L)
14 mmø × 3 000 mm (L) × 4
(0.55 inø) (117 in L)
12 mmø × 5 000 mm (L) × 2
(0.45 inø) (195 in L)
10 mmø × 3 000 mm (L) × 5
(0.4 inø) (117 in L)
3 Guide rope
8 mmø × 5 000 mm (L) × 1
(0.3 inø) (197 in L)
4 Nylon sling belts
100 mm (W) × 2 000 mm (L) × 2
(4.0 in) (78 in)
20 mm (W) × 4 000 mm (L) × 2
(0.8 in) (156 in)
5 Shackles
For 2.5 kg lond × 4 For 6 t load × 2 For 8 t load × 2
6 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.
50
7 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
8 Cylinder support
Height: 1 800 mm (70 in) × 1
9 V-block
V-block × 2 sets
10 Scaffolding
2 sets [Height about 3 000 mm (117 in)]
11 Oil containers
20 liter capacity × 4
10 liter capacity × 2
12 Standard tool kits
Prepare 4 or more sets.
13 Touch-up paint
Prepare 2 touch-up paint sets.
14 Pneumatic wrench (with compressor)
3 000 kgf·m (29 400 N·m/21 690 lbf·ft) capacity × 1 set
15 Hydraulic jack
For 20 t load × 2
16 Protectors and patches
Refer to Fig. 1 for an example protector.
Protector Used tire
Protector × 5
17 Hand tachometer or digital tachometer
Pulsemeter, Adapter
Engine speed sensor
18 Torque wrench
Fig. 1
60 kgf·m (600 N·m/435 lbf·ft) capacity
19 Safety belt × 4
20 Grinder
21 Halogen torch or charge detector
For detecting refrigerant leaks.
51
22 Thermometer probe
For measuring the refrigerant temperature.
−10˚C to 100˚C × 1
23 Pressure gauge
For measuring the pressure in the track link tension adjusting cylinder.
1960 Pa (200 kg/m2) capacity × 1
24 Miscellaneous
Rags, cleaning agent, lubricant, light and cord reel, grease, Molycoat spray.
25 Tap (Refer to next page)
M36 × P3.0
26 Lifting jig (Refer to next page)
1 set (2 pcs.)
52
Note:
For the tools which are not available locally,
SPECIAL TOOLS place order to Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Tap to be screwed
1 M36×P3.0 1 in bolt hole for
Tap tightening the
side frame
Fig. 2
4093798
Torque wrench
10 ~ 42 kgf·m Used to tighten
2 1
100 ~ 410 N·m the bolts.
75 ~ 305 lbf·ft
capacity
Fig. 3
4093800
Used to tighten
Power wrench
3 1 the side frame
With wrench, socket
to track frame
P/No. 4298389
Max. output torque

450 kgf·m (4 410 N·m/3 255 lbf·ft) Fig. 4
4229414 Used to tighten

4 Power wrench 1 the side frame
With wrench, socket to track frame
P/No. 4298388
Fig. 5
Lifting jig (R) Lifting jig Lifting jig of

(Right bracket) 1
superstructure
DWG. No. 8089397
5 Lifting jig (L) Refer to appendix
Lifting jig for a detailed
(Left bracket) 1 description of the
DWG. No. 8089392 use lifting jigs
Fig. 6
53
Note:
For tools which are not available locally,
SPECIAL TOOLS (Others) place an order with Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Vacuum pump
Assembly ST6905
Used to create
6 Vacuum pump ST6440 1 set vacuum in the
Hose ST6326 hydraulic tank
Nipple PT 1/8 ST6066
Nipple PT 3/8 ST6068
Fig. 7
54
NOTES
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56
ZX800/ZX850H Assembly Manual
SUPERSTRUCTURE
ASSEMBLY OF SUPERSTRUCTURE
6. Assembly of superstructure
6-1 Preparation
Superstructure assembly flowchart
Fig. 1
Step 1
Parts required
Item
Part No. Part name Q'ty Remarks
No. Shipping
Part List
(00) ––– ZX800 BASIC MACHINE 1 Superstracture + Track C/F Weight: 23 100 kg (50 820 lb)
(00) ––– ZX800 BASIC MACHINE 1 Superstracture + Track C/F + Track S/F Weight: 47 000 kg (103 400 lb)
00
(00) ––– ZX850H BASIC MACHINE 1 Superstracture + Track C/F Weight: 23 200 kg (51 040 lb)
(00) ––– ZX850H BASIC MACHINE 1 Superstracture + Track C/F + Track S/F Weight: 47 000 kg (103 400 lb)
Item
Part No. Part name Q'ty Remarks
No. Shipping
Part List
02 (02) ––– SIDE FRAME (R) 1
03 (03) ––– SIDE FRAME (L) 1
(05) 6017693 STEP 1 ZX800
04 (04) 6017693 STEP 1 ZX850H
(06) 6020843 STEP 1 ZX800
05
(03) 6020843 STEP 1 ZX850H
06
06 (08) 8088866 HANDRAIL 1 Right grab rail
07 (09) 7041515 HANDRAIL 1 Battery cover above
08
08 (10) 8083266 HANDRAIL 1 Fuel tank
09
09 (11) 7039946 HANDRAIL 1 Oil tank
12
10 (12) 7039947 HANDRAIL 1 Pump room
14
11 (14) ––– ANTENA ASS'Y 1 Cab radio
15
12 (15) ––– MIRROR ASS'Y RIGHT 1 Right back mirror
( )
Shipping Part List No.
59
Item
Part No. Part name Q’ty Remarks
No. Shipping
Part List
16
13 (16) ——— MIRROR ASS’Y LEFT 1 Left back mirror
14 (17) ——— HORN 2
19
15 (19) 7040954 PIPE; EXHAUST 1 Exhaust pipe
16 (33) ——— KEY 2
Spare parts
35
17 (35) 4391325 OIL; HYD 2 Replenishment Oil (HP46 (20 L): NISSEKI)
18 (37) 4218943 BOLT 36 Track S/F fix
38
19 (38) 4218944 SPACER 36 Track S/F fix
39
20 (39) 4242099 BOLT 8 Track S/F fix
40
21 (40) 4242098 SPACER 8 Track S/F fix
(42) 9212814 TOOL 1 ZX800
22 (51) 9212814 TOOL 1 ZX850H
(43) 4504952 HANDLE; RATCHET 1 ZX800
23
(52) 4504952 HANDLE; RATCHET 1 ZX850H
Spare parts
(44) 4061488 PIPE 1 ZX800
24 (53) 4061488 PIPE 1 ZX850H
(45) 9159210 SPARE-PARTS 1 ZX800
25 (50) 9159210 SPARE-PARTS 1 ZX850H
(47) ——— NAMEPLATE 1 ZX800
26 (47) 2045102 NAMEPLATE 1 ZX850H
(49) ——— WIPER ASS’Y 1 Blade + arm ZX800
27 (55) ——— WIPER ASS’Y 1 Blade + arm ZX850H
(50) ——— LIGHT ASS’Y 2 Upper cab light with bracket ZX800
28 (56) ——— LIGHT ASS’Y 2 Upper cab light with bracket ZX850H
(52) M923003 BOLT 8 T/F Fixing bolt (ZX800)
29 (78) M923003 BOLT 8 T/F Fixing bolt (ZX850H)
(53) M923011 BOLT 8 T/F Fixing bolt (ZX800)
30 (79) M923011 BOLT 8 T/F Fixing bolt (ZX850H)
(54) 4114408 WASHER 16 ZX800
31 (80) 4114408 WASHER 16 ZX850H
(55) 4218945 SPACER 8 ZX800
32 (81) 4218945 SPACER 8 ZX850H
(56) 4243157 SPACER 8 ZX800
33 (82) 4243157 SPACER 8 ZX850H
(57) 4207766 PLATE; LOCK 4 ZX800
34 (83) 4207766 PLATE; LOCK 4 ZX850H
(58) 4333844 GUIDE 4 ZX800
35 (84) 4333844 GUIDE 4 ZX850H
36
36 (60) 6019867 DUCT 1 Duct rear with net (ZX800/ZX850H)
36
36 (58) 5008407 DUCT 1 EN Duct rear with net (ZX850H-EN)
37 (61) 6019868 DUCT 1 Duct front with net (ZX800/ZX850H)
37 (59) 5008408 DUCT 1 Duct front with net (ZX850H-EN)
(62) 8082979 COVER 1 Duct visor (ZX800/ZX850H)
38 (60) 8082979 COVER 1 Duct visor (ZX850H-EN)
(64) J222014 WASHER 4 ZX800/ZX850H
39 (62) J222014 WASHER 4 EN Duct rear with net (ZX850H-EN)
(65) A590914 WASHER; SPRING 4 ZX800/ZX850H
40 (63) A590914 WASHER; SPRING 4 EN Duct rear with net (ZX850H-EN)
(66) J901406 BOLT 4 ZX800/ZX850H
41 (64) J901406 BOLT 4 EN Duct rear with net (ZX850H-EN)
(67) J021200 BOLT; SEMS 3 ZX800/ZX850H
42
(66) J021200 BOLT; SEMS 3 EN Duct rear with net (ZX850H-EN)
(69) 8069333 STEP 4 Track side step upper ZX800
43 (42) 8069333 STEP 4 Track side step upper ZX850H
(42) 8068391 STEP 4 Track side step upper ZX800 (USA)
60
Item
No. Shipping
Part List
(70) 8068378 STEP 4 Track side step lower ZX800
44
(43) 8068378 STEP 4 Track side step lower ZX850H
(71) J901650 BOLT 32 Track side step fix ZX800
45
(44) J901650 BOLT 32 Track side step fix ZX850H
(73) 6021470 COVER 1 Travel piping cover (Right front) For ZX800
46 (69) 6019840 COVER 1 Travel piping cover (Right front) For ZX850H
(74) 6021479 COVER 1 Travel piping cover (Left front) For ZX800
47
(70) 6019841 COVER 1 Travel piping cover (Left front) For ZX850H
(75) 7043553 COVER 1 Travel piping cover (Right rear) For ZX800
48
(71) 7039800 COVER 1 Travel piping cover (Right rear) For ZX850H
(76) 7043554 COVER 1 Travel piping cover (Left front) For ZX800
49 (72) 7039801 COVER 1 Travel piping cover (Left front) For ZX850H
(77) 8082865 COVER 1 Travel piping cover (Right side) For ZX800
50 (73) 8082865 COVER 1 Travel piping cover (Right side) For ZX850H
(78) 8082866 COVER 1 Travel piping cover (Left side) For ZX800
51 (74) 8082860 COVER 1 Travel piping cover (Left side) For ZX850H
(79) 8060558 COVER; (R) 1 Fix bolt cover (Right) For ZX800
52 (75) 8060558 COVER; (R) 1 Fix bolt cover (Right) For ZX850H
(80) 8060559 COVER; (L) 1 Fix bolt cover (Left) For ZX800
53 (76) 8060559 COVER; (L) 1 Fix bolt cover (Left) For ZX850H
(＊＊) 8088575 HANDRAIL 1
( )
No. on shipping part list
Item
No. Shipping
Part List
58
54 (58) 8088628 BOX 1 For the ZX850H pre-cleaner
59
55 (59) 4282499 CLAMP; HOSE 2 ZX850H
60
56 (60) 4464993 HOSE; AIR 1 ZX850H
61
57 (61) 4465368 CLEANER; PRE 1 ZX850H
62
58 (62) ——— BAND 1 For fixing the ZX850H pre-cleaner and box; included in the band kit
Item
No. Shipping
Part List
(00) 5007324 COUNTER WEIGHT 1 STD.
59
(00) 5008037 COUNTER WEIGHT 1 Use when the counterweight removal/installation device is attached
(01) 4345741 SHIM 4 STD.
60 (01) 4345741 SHIM 4 Use when the counterweight removal/installation device is attached
61 (02) 9701925 PIN; RING 2 Use when the counterweight removal/installation device is attached
(03) 4335906 WASHER 2 STD.
62 (03) 4103743 WASHER 2 Use when the counterweight removal/installation device is attached
(04) 4345718 NUT; U 2 STD.
63
(04) 4246150 NUT; CASTLE 2 Use when the counterweight removal/installation device is attached
(05) 4405145 BOLT 2 STD.
64
(05) 4341856 BOLT 2 Use when the counterweight removal/installation device is attached
65 (06) 4346036 SPACER 2
66 (07) 4221465 STOPPER 2
67 (08) J912470 BOLT 4
68 (09) A590924 WASHER; SPRING 4
(10) 4335904 WASHER 2 STD.
69
(10) 4114413 WASHER 2 Use when the counterweight removal/installation device is attached
70 (11) 4380636 SHIM 4
71 (12) 4380637 SHIM 2
72 (15) 6019895 HANDRAIL 1
73 (16) 6019896 HANDRAIL 1
( )
No. on shipping part list
61
6-2 Connecting the side frames to the track frame
Step 1
Side frame (left) 03
Fitting the side frames
1 Cleaning the left side frame 03

a
1 Position side frame (L) 03 as indicated in Fig. 1.
2 Use a tap to clean all bolt holes in each mounting b
face a and b of the side frame.
Tap size: M36 × P3.0
3 Clean the mounting faces of the side frame.
Check each mounting face for damage or
scratches.
Note:
Fig. 1
If the mounting face surface is damaged or
Detail A
scratched, repair or re-finish it.
2 Attaching wire ropes to the superstructure

Attach wire ropes to superstructure 00 as indicated in Tap
Fig. 3.
Notes:
i) Use bolts to install lifting jigs on the
counterweight mounting face.
Refer to Appendix for a detailed description of
Fig. 2
the use of lifting jigs.
ii) Install protectors to the left and right of the front Wire rope Lift
of the main frame (2 locations), as depicted. 34 mmø × 3 000 mm Wire rope
Chain block 34 mmø ×
Superstructure assembly weight: 6 ton 10 000 mm
ZX800 23 100 kg (50 820 lb)
ZX850H 23 200 kg (51 040 lb) Wire rope
34 mmø × 3 000 mm
Shackle
Wire ropes 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): 2 pcs.

Bolt
Protector: 2 pcs.
Protector
Shackle (for 6 tonne load): 2 pcs.
Lifting jig
00
Lifting jig: 1 set Fig. 3
3 Cleaning the track frame 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 Clean faces c ~ f of the track frame
(4 locations - left/right of the front & rear).
2 Thoroughly clean all bolt holes in the track frame.
3 Check each mounting face surface for damage or
scratches.
Note: c d Wooden block

scratched, repair or re-finish it. Fig. 4
e f
62
Hold
4 Preparing the side frames and superstructure for
connection
1 Hold superstructure 00 level.
Note:
00
Level the superstructure by adjusting the preset
chain blocks.
CAUTION:
Never allow anyone to stand directly beneath the lifted
superstructure.
2 Rotate the track frame. Track frame

A
If the track frame is set to orientation A relative to Fig. 5
the superstructure, start the engine and rotate the
track frame by 90°, as indicated in Fig. 6 ( B ).
Notes:
i) In rotating the track frame, the superstructure
Hold
must not be able to move after starting the
engine.
Before starting the engine, check the radiator
and oil levels as described in the user’s manual.
ii) Rotate the track frame slowly, and position sub-
leaders at the front and rear of the
superstructure to direct the procedure.
90°
B
Fig. 6
Track frame
3 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
63
Lift
5 Installing the left side frame (L)

Move
1 Slowly move the superstructure toward the side
frame.
2 Align the bolt holes in the track frame and side
frame.
3 Apply lubricant to the screw and underside of the
head of bolts 18 and 20 .
Side frame (L)
Notes:
i) Use lubricant made from white zinc and spindle
oil mixed in 1:1 proportions.
Travel piping
ii) Before installing the bolts 18 and 20 , apply
lubricant to the screw and underside of the bolt
head (＊ in Fig. 10). Fig. 8
4 Manually screw in bolts 18 fitted with spacers 19

18 sets.

4 sets.
Notes:
Bolt ＊
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 ＊
Spacer
types A and B (see Figs. 11 and 12).
Fig. 10 Fig. 9
iii) Tighten each bolt until the mating faces make
firm contact.
18
iv) Check that the mating faces meet snugly. A
B 20
19
21
Detail B
Bolt A Bolt B
18 20
× 19 (8) ×4
183 Fig. 11
233
Spacer
Spacer Ratchet wrench
19
21
60 × 19 (8) ×4
110
Fig. 12
6 Tighten bolts 18 and 20 fitted in steps 4 and 5

above, with a ratchet wrench.
Fig. 13
64
7 Tighten the bolts with a power wrench to the
specified torque.
A
Tightening torque: Bolts A , B 285 kgf·m B power wrench
(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. 14
8 Fit guides 35 using bolts 30 , washers 31 and 29

spacers 33 .
9 Fit lock plates 34 using bolts 29 , washers 31 and 31
spacers 32 . 34 32 30
10 Tighten the bolts to the specified torque using a
power wrench. 31
35
Tightening torque: 285 kgf·m
(2 795 N·m/2 060 lbf·ft)
33
CAUTION:
Be careful that your hands are not caught by the Fig. 15
Detail C
29 30
×4 ×4
159
31 35
31
×2
34
33
×2
32
×4
×4
60 40 Fig. 16
65
11 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 Lower
about 150mm (6 in) to 200mm (8 in) above
horizontal.
Wooden blocks: 2 pcs.

Track frame
Note:
The wooden blocks must each be able to support a
load of at least 10 tonnes.
CAUTION: 150 ~ 200mm

(6 ~ 8 in)
Lowering the track frame onto blocks makes the Wooden block (× 2)
subsequent work safer than keeping the superstructure
suspended with a crane. Fig. 17
12 Remove the wire ropes and lifting jigs attached to Remove

the superstructure.
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.

(90 N·m/65 lbf·ft)
Fig. 19
66
Step 3
Installing the right side frame (Right)
1 Preparing the superstructure

Swing
180°
1 Start the engine and slowly rotate the
superstructure 180°.
Note:
Rotate the track frame slowly, and position sub-
leaders 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)

2 Cleaning the right side frame 02
1 Use a tap to clean all bolt holes in each mounting b

face b and c of side frame 02 .
c
Tap size: M36 × P3.0
2 Clean the mounting faces of the side frame.

Check each mounting face for damage or
scratches.
Fig. 21
Detail D
Note:
scratched, repair or re-finish it. Tap
Fig. 22
67
Hold
3 Attaching wire ropes to the right side frame
1 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 02
indicated in Fig. 23.
Side frame assembly weight:

ZX800 (650 mm shoes): 11 600 kg (25 520 lb) Protector
ZX800 (750 mm shoes): 11 950 kg (26 290 lb)
ZX850H (650 mm shoes): 11 700 kg (25 740 lb)
Wire ropes:
26 mmø × 8 000 mm (L) : 2 pcs.
＊
(1.0 inø) (312 in) About 1 800 mm
Protectors: 4 pcs. Fig. 23

Travel motor
2 Lift the side frame.
CAUTION:
Make sure that no-one enters underneath the lifted
side frame.
Notes:
i) 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 Lower Raise
Attach wire Raise Position a On relifting the side

ropes to vertically. wooden block frame, it should be
the side underneath tilted as depicted.
frame. the outside
edge of the
side frame and
momentarily Connection with the
lower the side superstructure can be
frame onto the carried out smoothly
Inside Outside block. with the side frame in
(2 pcs.) this state.
Wooden block
Fig. 24
Wooden block: 2 pcs.

for 1 000 kg (2 200 lb) load
68
Raise
4 Installing the right side frame Move
1 Move the lifted right side frame toward the track

frame.
Side
Move the side frame horizontally in the direction of frame (R)
the arrow, and align the bolt holes in the track
frame and side frame.
2 Apply lubricant to the screw and underside of the

head of bolts 18 and 20 .
Fig. 25
Notes:
Hold
i) Use lubricant made from white zinc and spindle
ii) Before installing the bolts 18 and 20 , apply
lubricant to the screw and underside of the bolt
head (＊ in Fig. 29).

Fig. 26
18 sets.

4 sets.
Notes: Detail F
i) Note that using excessive force in screwing in
bolts can lead to damage to the thread. Torque wrench
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 Tighten bolts 18 and 20 fitted in steps 3 and 4

above, with a ratchet wrench.
Fig. 27
Detail G
Bolt A 20
Detail H Bolt B 18
Bolt ＊ ×4 × 18
183
233
Chamfering Spacer 21 Spacer
19
＊
×4
Section 60 × 18
110
Spacer Fig. 28
Fig. 29
69
6 Tighten the bolts with a power wrench to the Detail I
specified torque.

(2 795 N·m/2 060 lbf·ft)
CAUTION: Power wrench

Fig. 30
7 Fit guides 35 using bolts 30 , washers 31 and 30

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

(2 795 N·m/2 060 lbf·ft)
CAUTION:
Fig. 31
Detail J
30 29
×4 ×4
159
129 31 35 31
×2
34
×2
32
33
×4
×4
40 60
Fig. 32
70
Step 4
Removing the wooden blocks Hold
1 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.
Fig. 33
Jack Wooden wooden blocks
block
Hold
2 Remove the wooden blocks, and lower the side

frame such that it rests on the ground.
Remove
the
wooden
blocks
Fig. 34
3 Remove the wire ropes from the side frame.

Remove
wire ropes
Fig. 35
2 Changing the orientation of the superstructure Rotate the

superstructure 90˚
Start the engine and rotate the superstructure 90° such

that the cab faces forward.
Note:
Rotate the track frame slowly, and position sub-
leaders at the front and rear of the superstructure to
direct the procedure.
Fig. 36
71
Step 5
Connecting the travel motor hoses
1 Removing the travel motor covers
1 Remove travel motor cover a .

2 Remove the travel motor cover for the opposite
side frame.
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.
1 Remove the caps from the travel motor ports and
travel hoses.
a Fig. 37
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 travel hoses b , c , d and e to the Tightening torque: b , c : 11 kgf·m
travel motor. (110 N·m/80 lbf·ft)
Number tags are provided on each port and hose. d : 18 kgf·m
Connect the hoses, matching the numbers. (175 N·m/130 lbf·ft)
e : 9.5 kgf·m
3 Connect the travel hoses for the opposite travel (95 N·m/70 lbf·ft)
motor in the same manner.
Notes:
i) Connect the hose so it does not make contact
Detail K
with other parts. b c d e
ii) Make sure that no dust has adhered to the seat
face of the hose.
iii) Do not damage the joining surfaces of the hose.
iv) Do not twist hoses when connecting them.
Their service life will be shortened.
v) Use O-rings to connect the hoses. Apply a thin
layer of sealant #98D to the O-ring before
installation.
3 After connecting the travel motor hoseing, clean
away any residue oil from the outside of all parts.
Detail L
Fig. 38
b c e
A
Fig. 39
72
4 Reinstalling the travel motor piping covers
1 Reinstall travel motor cover a removed in step-5

a
1 above.
2 Install travel motor piping covers 46 , 48 , 50 and 52 .
3 Install travel motor cover a and travel motor
piping covers 47 , 49 , 51 and 53 for the opposite
travel motor, in the same manner.

(205 N·m/150 lbf·ft)
Notes:
Fig. 40
i) Apply lubricant to the thread of the mounting
bolts before installation.
ii) Hand screw in all bolts first, before tightening to 50
the specified torque.
52
46
48
Fig. 41
Fig. 42
73
Step 6
Installing the steps and handrails
1 Install steps 43 and 44 to the side frame using bolts 45 ,

washer, spring washer.

(205 N·m/150 lbf·ft) 43
Notes:
i) Apply lubricant to the thread of the mounting 44 43
ii) Hand screw in all bolts first, before tightening to 44 Fig. 43
iii) Install the steps for the opposite side frame in
the same manner.
2 Install steps 04 and 05 to the superstructure.

(90 N·m/65 lbf·ft)
Notes:
i) Apply lubricant to the thread of the mounting 04
Fig. 44
ii) Hand screw in all bolts first, before tightening to 05
the specified torque. 09
10
3 Install handrails 09 and 10 to the oil tank.

(90 N·m/65 lbf·ft)
Notes:
ii) Hand screw in all bolts first, before tightening to
Fig. 45
4 Install handrails 07 and 08 to the fuel tank. 07 08

(90 N·m/65 lbf·ft)
Notes:
Fig. 46
74
Step 7
Accessory installation
FOR ZX800
Antenna 11 28 28 27
Handrail a
1 Install the side mirrors
13
Use bolts to install side mirror assemblies 12 and 13 to
their respective stay/clamp, as illustrated in Figs. 47
12
and 48.
(10 N·m/7.2 lbf·ft) 06
2 Install the windscreen wiper

＊＊
1 Install windscreen wiper assembly 27 as
illustrated in Figs. 47 and 48.
2 Connect electric wire coupler.
Note:
Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
3 Install the head lamps

Fig. 47
1 Install head lamp assemblies 28 as illustrated in
Fig. 47. FOR ZX850H The head lamps are built into
the head guard for ZX850H
machines
Tightening torque: 9 kgf·m 27
Handrail a Antenna 11
(95 N·m/65 lbf·ft) 13
2 Connect electric wire coupler.
12
Note:
Before connecting the electric wires, remove the 06
Note: ＊＊
This procedure is not necessary for ZX850H
machines, as the head lamps are built into the head
guard. (See Fig. 48).
4 Install handrail to the side of the superstructure as

illustrated in Figs. 47 and 48. (When installing the 900G
shoe)
(95 N·m/65 lbf·ft) Fig. 48
Notes: 6 Installing the antenna

i) Apply lubricant to the thread of the mounting 1 Install antenna 11 as illustrated in Figs. 47 and 48.
bolts before installation. 2 Connect electric wire coupler.
the specified torque. Note:
5 Install handrail 06 to the side of the superstructure as anti-corrosive and any rust from the couplers.
illustrated in Figs. 47 and 48.
7 In order to facilitate the easy installation of the boom
foot pins, temporarily remove handrail a , attached to
(95 N·m/65 lbf·ft)
the superstructure. (This handrail is reinstalled at the
Notes: completion of boom installation.) See Figs. 47 and 48.
i) Apply lubricant to the thread of the mounting Note:
bolts before installation. Be careful not to damage the rearview mirror 12
ii) Hand screw in all bolts first, before tightening to attached to the handrail, during removal.
75
Accessory installation (Pre-cleaner and horn) Detail M
8 Install the pre-cleaner a
1 Cap a is attached to the air intake port in the air Fig. 49

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

(60 N·m/43 lbf·ft)
Notes:
Fig. 50
Detail N
57
58
54
55
56
9 Install the horns
55
Fig. 51
1 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.

(30 N·m/20 lbf·ft)
Notes:
Fig. 52
ii) Hand screw in all bolts first, before tightening to Detail O
the specified torque. 14 Hi
14 (blue)
2 Connect the electric wire couplers for the horns.

Lo (red)
Fig. 53
Note:
Fig. 54
76
Accessory installation (Ducts, cover and caution plate) Detail P
37
10 Install ducts 36 , 37 , and cover 38 . Ducts 36 and 37
36
conform with the EN specification.
38
Note:
Use washer 39 , spring washer 40 , bolt 41 , and sems
bolt 42 to install the ducts and covers.
37
Tightening torque M10: 5 kgf·m
(50 N·m/36 lbf·ft)
Tightening torque M12: 9 kgf·m 36
(90 N·m/65 lbf·ft) 36 , 37 , 38
Tightening torque M14: 14 kgf·m Disassembled parts
(140 N·m/100 lbf·ft) ~S/No. 6195
Tightening torque M16: 21 kgf·m
(205 N·m/150 lbf·ft)
38
Notes: 37
bolts before installation. 36
ii) Hand screw in all bolts first, before tightening to 36 , 37 , 38
the specified torque. Assembled parts
S/No. 6196~
iii) Machines with serial no. 6196 and up have one- Fig. 55
piece 36 , 37 , and 38 . However, those for EN
remain unchanged as shown here.
11 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
26
Fig. 57
Fig. 58
77
6-3 Mounting the counterweight
Step 1
Mounting the counterweight
1 Remove covers a and b from underneath the

superstructure before installing the counterweight.
Cover b
Cover a Fig. 1
2 Attaching wire ropes to the counterweight Lift
1 Attach wire ropes to counterweight 59 as indicated

in Fig. 2.
Counterweight: 12 500 kg (27 000 lb) Wire rope

24 mmø×
Wire ropes: 2 pcs. 10 000 mm
24 mmø × 10 000 mm (L)
(0.9 inø) (390 in L)
Shackle
Counterweight 59
2 Adjust the wire rope to make the counterweight
level.
CAUTION:
Never allow anybody to stand directly beneath the
lifted counterweight.
Fig. 2
78
Lift
3 Installing the counterweight
Move
1 Slowly move the counterweight towards the main

frame, such that the projection on the
counterweight connecting face mates with the 60
mounting holes in the main frame.
59
CAUTION:
Never allow anyone to enter into the area under the
lifted counterweight. 63
62 Apply
lubricant
to the
2 Install counterweight mounting bolts 64 and base of
spacers 65 (external diameter 80 mm). the bolt
head
3 Temporarily install shims 60 , washers 62 (external ＊
diameter 90 mm) and castle nuts 63 on bolts 64
from the main frame side. ＊ 64
65 Apply lubricant
to the thread
Fig. 3
Notes:
i) Before installing the bolts 64 , apply lubricant to Detail A
the screw and underside of the bolt head (＊ in 64
65
Fig. 3).
Use lubricant made from white zinc and spindle
60
ii) Tighten each bolt until the mating faces make
firm contact.
iii) Check that the mating faces meet snugly.
63 62
Note: Fig. 4
Shims 60 must be installed in the orientation
depicted in Fig. 4. Make sure that the shims are Hold
installed in such a way as to keep the nuts from
loosening.
Fig. 5
79
4 Securing the counterweight in place Detail B
1 Tighten counterweight mounting bolts 64 such that

the counterweight is flush against the main frame.
2 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 Fig. 6
main frame. Hold

3 Tighten counterweight mounting bolts 64 .
63 62 60
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: 70 71 65
Width Across flats of nut or castle nut 63 66
70 mm (with counterweight removal/installation device) 64
75 mm (STD.)
Note:
After tightening the bolt to the specified torque, 67
secure castle nut 63 with ring pin 61 if the 68
counterweight is provided with the counterweight Fig. 7
removal/installation device. 69
Counterweight mounting bolt tightening torque:

Detail C
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)
Note:
Tighten the bolts with a power wrench.
66
CAUTION:
68
67
69 70 71 Fig. 8
4 Tighten the bolts fixed to the counterweight
projection.
Locking plate tightening torque: 70 kgf·m Remove the

690 N·m/510 lbf·ft wire ropes
Notes:
5 Finishing up
1 Remove the wire ropes and shackles attached to

the counterweight.
2 Reinstall covers a and b removed in 1 .
Tightening torque: 9 kgf·m b

(90 N·m/65 lbf·ft)
a Fig. 9
80
6 Install, handrails 72 and 73 on the counterweight.

(90 N·m/65 lbf·ft)
Notes:
Fig. 10
72 73
Fig. 11
Step 2
Touch-up painting and final check
1 Touch-up painting
After completing the above steps and installing the
handrails, touch-up the paintwork.
Fig. 12
Detail D
2 Final checks of the superstructure
Check that all the bolts on the superstructure have
been tightened to the prescribed torque.
Fig. 13
81
6-4 Greasing of swing bearing
Greasing (1) Detail A
1 The machine is provided with a pneumatically operated a

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 b
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.
c
Fig. 1
2 Start the engine.
3 Supply grease to 3 points as shown in Fig. 3.
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 Fig. 2
front pins with the air grease gun manually.

Detail B
iii) Insufficient greasing will cause wear to the pins.
Swing bearing Swing bearing
Swing bearing Fig. 3
82
4 Lubrication method
(1) Turn power switch d ON to activate the pump.

Grease is sucked up and supplied to high-pressure d
grease gun b .
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 a
air-mixed grease is bled out.
(2) Grab high-pressure grease gun b and pay out the Fig. 4
hose from hose reel c to the length required.
(3) Press hydro-chuck g protruding from high-

pressure 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,
g
is taken, as follows:
f
· Tip nozzle f a little so as to release the connecting
b
pressure applied to hydro-chuck g .
· Slowly detach hydro-chuck g from nipple h .
(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 c
the components. A little grease will be discharged Fig. 5
at this time.
g
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
83
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.
Fig. 1
1 Check the coolant levels a in the radiator (See Figs. 1
and 2). If the level is low, refill through the filler ports b Detail B
on the radiator.
Refer to the OPERATION MANUAL for details.
IMPORTANT:
Do not remove the radiator cap while the coolant is still
hot, as high temperature coolant may gush out of the b
radiator causing injury.
Instead, gradually loosen caps b once the coolant
temperature has dropped.
Fig. 2
Check that the coolant level is between the HIGH and
LOW marks on the level gauge. Remove the radiator Detail C
cap and add coolant if the level is low.
2 Check the oil levels c in all reduction gears for swing

c
reduction devices.
CAUTION:
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels. Fig. 3
Detail D
3 Check the oil level d in the engine oil pan.
d
CAUTION:
the oil levels.
4 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. e
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
84
5 Check the fuel level in the fuel tank. Detail F
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 Fig. 6
gal).
Detail H Detail G
Fig. 8 Fig. 7
Detail I
Fuel level
gauge c
Fig. 9
Fig. 10
Detail J
6 Check the pump transmission oil level.
1 Remove dipstick d . Oil must be between the

marks.
2 If necessary, add oil after returning the dipstick to
its original position.
d
CAUTION:
the oil levels.
Fig. 11
85
Detail K
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
7 Checking the hydraulic oil level.

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
a
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.
2 Checking the liquid level of battery and specific
gravity.
Fig. 14
Detail M
Connecting the battery cable Fig. 15
86
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 Remove plug a from the top of each pump side

to release trapped air.
2 Fill the pumps with oil and temporarily tighten the
plug a .
3 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 Fig. 1
LOCK position.
4 Slowly loosen the plug a to release trapped air.
Retighten the plug a when air stops and oil flows
from the hose ends. Detail A
5 Purge air from the hydraulic system by running the
a
engine at slow idle and operating all control levers
slowly and smoothly for 15 minutes.
6 Position the machine with the arm cylinder fully
retracted and the bucket cylinder fully extended.
7 Lower the bucket to the ground.
Note:
Follow steps 6 and 7 above only when the front
attachment is installed.
8 Turn the auto-idle switch off. Fig. 2

9 Stop the engine. Remove the key from the key
switch.
10 Pull the pilot control shut-off lever to the LOCK
position.
11 Check the hydraulic oil tank gauge. Add oil if
necessary.
1 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!
2 Confirm hydraulic oil level in the hydraulic tank. Add

hydraulic oil if required.
3 After the oil has flowed out clean the parts carefully.
87
6-7 Trial operation of superstructure
Trial operation
1 1 Start the engine.

2 Check the operation of the gauges.
3 Check the travel and swing functions.
Swing
CAUTION:
This operation must be done slowly. Avoid abrupt
operation!
4 Check for oil leakage. Confirm that there is no oil
leaking from the assembled areas.
5 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.
CAUTION: Fig. 1
Make sure nobody other than the operator is in or on

the hydraulic excavator before starting the operation.
Traveling Fig. 2
2 Confirm that machine noise is maintained at specified

levels.
Detail A
Fig. 4 Fig. 3
88
NOTES
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89
NOTES
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90
MOUNTING PROCEDURE FOR

FRONT-END ATTACHMENTS
ATTACHMENTS
BACKHOE FRONT
7. Backhoe front mounting procedure
7-1 Preparation
Backhoe front assembly flowchart
Fig. 1
Step 1
Parts required
Item
No. Shipping
Part List
00 (22) 4331075 CYL., BOOM (R) 1
01 (23) 4331076 CYL., BOOM (L) 1
02 (25) 4089703 FLANGE; SPLIT 8 Boom cyl.
03 (26) M341445 BOLT; SOCKET 16
04 (28) 4450978 HOSE 2 Boom cyl. rod
05 (29) 4414282 HOSE 2 Boom cyl. bottom
06 (30) 4508805 O-RING 6 Boom cyl. bottom + rod
07 (31) 4187328 O-RING 2 Boom cyl. rod
( )
No. on Shipping part list
93
Item
No. Shipping
Part List
(00) ——— BOOM 1 With arm cylinder (STD/HD)
08 (00) ——— BE BOOM 1 With arm cylinder (BE)
(02) ——— ARM 1 With bucket cylinder (STD/HD)
09 (02) ——— BE ARM 1 With bucket cylinder (BE)
(04) ——— BUCKET 1 (STD/HD)
10 (04) ——— BUCKET (4.3 m3 ROCK) 1 (BE)
(06) 4373644 HOSE 2 (STD/HD)
11
(06) 4364317 HOSE 2 (BE)
(07) 4508805 O-RING 6 (STD/HD)
12 (07) 4508805 O-RING 5 (BE)
13 (08) 4510169 O-RING 3 (STD/HD/BE)
(10) 4379158 PLATE, THRUST 2 (STD/HD)
14
(10) 4386485 PLATE, THRUST 2 (BE)
(＊＊) 4487585 O-RING 4 (STD/HD)
15
(＊＊) 4487581 O-RING 4 (BE)
(13) 4379157 PLATE, THRUST 2 (STD/HD)
16 (11) 4386486 PLATE, THRUST 2 (BE)
(15) ——— LAIT ASSEMBLY 2 (STD/HD)
17 (16) ——— LAIT ASSEMBLY 2 (BE)
( )
94
7-2 Mounting the backhoe front
Step 1
Note: Do not completely detach the pin
Preparing the base machine
1 Preparing the base machine
1 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.
Fig. 1
2 Clean away the anti-corrosive applied to the boom
foot pins and pin holes.
3 Apply grease to the boom foot pin and pin holes. Lift
Step 2
Installing the boom cylinders Wire rope

12 mm ø × 5 000 mm
1 Attaching wire ropes to the boom cylinders
1 Attach wire ropes to boom cylinder (L) 01 as

Boom cylinder weight: 700 kg (1 540 lb)
Wire ropes:
12 mmø × 5 000 mm (L) : 2 pcs.
(0.45 inø) (195 in L)
01
2 Clean away the anti-corrosive applied to bottom a
and rod boss a and b of the boom cylinder.
3 Apply grease to boss a and b .
2 1 Lifting boom cylinder 01

Fig. 2
2 Lift the boom cylinder, keeping it level.
b
Note:
The left and right boom cylinders differ in the
manner depicted in Fig. 3. Be sure not to mix them
00 Right boom cylinder
up. Hydraulic
piping
01 Left boom cylinder Fig. 3
95
3 Preparing the boom cylinder foot pins for installation
1 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 inside-
facing bracket.
ii) Shims are attached to foot pins a and b which
a
are to be used during pin installation.
b
2 Clean away the anti-corrosive applied to the boom Fig. 4
foot pins and pin holes. Hold
3 Apply grease to the boom foot pins and pin holes.
Move
4 Installing boom cylinder (L) 01
1 Move the boom cylinder toward the base machine, Bolt

such that the bottom boss of the boom cylinder Spring washer
aligns with the frame boss. Plate
b
Note:
Install the boom cylinder such that the hydraulic
piping faces downward.
01
2 Align the pin holes of the boom cylinder and base
machine. Install the boom cylinder
with the hydraulic piping
3 Check the size of clearance c . facing downward.
If c is more than 4mm, fit the shim attached to
Fig. 5
the pin, on the side away from the pin head.
4 Insert pin b , being careful not to damage the seal Detail A
on the cylinder. Shim Pin b
5 Fit and tighten the plate with bolts and spring
washers.
Plate
Note:
Clearance
Apply lubricant to the pin before installation. c
Bolt, Cab side
spring washer
Fig. 6
(390 N·m/290 lbf·ft)
5 Lower the boom cylinder onto a cylinder support such

that it is maintained level. Install boom cylinder 00 in 00
the same manner as described above.
Note:
Place a V-block shaped rest under the top of the 01
boom cylinders to protect the hydraulic piping. V-block
Cylinder support: 1 pc.

Height: 1 800 mm (70 in) Boom cylinder support
V-block: 2 pcs.
Fig. 7
96
Step 3 Boom
Connecting the boom cylinder hoses cylinder hoses 05
(Out side)
1 Connecting the boom cylinder hoses

Boom cylinder 04
Note: rod hose
(In side)
1 Remove the caps from the ends of the hoses.
CAUTION:
2 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

(140 N·m/100 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 make contact
with other 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.
v) Use O-rings 06 (P/No. 4508805) and 07 (P/No.
4187328) to install the hoses. Apply a thin layer 2 After connecting the hoses, clean away any residue oil
from the outside of all parts.
of sealant #98D to the O-rings before
installation.
Step 4
Bleeding the boom cylinders
1 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
Boom cylinder
inside, repeating the process until the cylinder rods
extend at constant speed.
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. Fig. 9
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.
2 After completely bleeding the boom cylinders of air,

retract them in preparedness for the next step.
97
Step 5 08
Wooden
Reparation of the boom block
Arm cylinder
1 Place wooden blocks under boom 08 as shown in Fig.
10.
Boom 08 weight:
STD 8 500 mm 7 090 kg (15 600 lb)
H 8 620 mm 7 610 kg (16 740 lb)
BE 7 500 mm 7 200 kg (15 840 lb)
Long 10 310 mm 8 020 kg (17 645 lb)

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).
Detail B
2 Secure the arm cylinder rod with wire ropes and a lever Wire rope
block, as shown in Figs. 10 and 11. Lever block
Wire ropes: 2 pcs.

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

for a 1 metric tonne (1.1 US ton) load
CAUTION:
Securing this wire rope and lever block in place
Fig. 11
prevents the cylinder rods from being extended. Be
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident.
Detail C
Urethane
Note: foam sleeve a
The lever block secure the arm cylinders and
prevent the cylinder rods from extending during the
work.
Plated
cylinder rod Arm cylinder
3 Remove urethane foam sleeves a , fitted as protection

Fig. 12
on the plated arm cylinder rod.
98
Step 6
Preparation of the arm
1 Place wooden blocks under arm 09 as shown in Fig.

13.
Arm 09 weight: 09
STD 5 065 mm 3 590 kg (7 900 lb)
H 5 065 mm 4 010 kg (8 820 lb)
BE 4 410 mm 4 350 kg (9 570 lb)
Semi long 5 820 mm 3 900 kg (8 580 lb)
Long 6 820 mm 3 990 kg (8 780 lb) Wooden
block
Size: 500 mm (L) × 500 mm (W) × 500 mm (H)
Fig. 13
(20 in) (20 in) (20 in)
Note:
Each wooden block must be able to carry a load of
at least 2 500 kg (5 500 lb).
Bucket cylinder
2 1 Clean off the anticorrosive from the pins a and c

b inserted into the arm top. b
2 Extract the pins a and b from the arm top. a
3 Clean pin holes a and b .
4 Clean off the anticorrosive applied to the pins c d
inserted into the arm.
5 Extract pins c from the arm.
6 Clean pin holes c and d in the arm. Fig. 14
3 Remove urethane foam sleeves e , fitted as protection Detail D

on the plated bucket cylinder rod. Urethane
foam sleeve e
Plated Bucket cylinder

cylinder rod
Fig. 15
99
4 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
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being extended. Be Fig. 16
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident.
Detail E
Wire rope
Note:
Lever block
The lever blocks secure the bucket cylinders and
prevent the cylinder rods from extending during the Wire rope
work.
Bucket cylinder
Fig. 17
100
a x2 b x2
Step 7
Preparation of the bucket
1 1 Position bucket 10 . 10
Bucket 10 weight: 1.8 m3 1 870 kg (4 115 lb)

2.0 m3 2 060 kg (4 530 lb)
2.4 m3 2 350 kg (5 170 lb)
2.8 m3 2 400 kg (5 280 lb)
2.9 m3 2 500 kg (5 500 lb)
3.4 m3 2 650 kg (5 830 lb)
4.3 m3 BE 3 580 kg (7 875 lb)
3.4 m3 ROCK 3 460 kg (7 610 lb)
Fig. 18
3.6 m3 BE-H ROCK 3 490 kg (7 680 lb)
4.3 m3 BE-ROCK 4 100 kg (9 020 lb) Detail F
O-ring 15
2 Clean pin holes a x2 and b x2, as shown in Fig. O-ring 15
18.
2 Reinstall the pins a and b removed from the arm, as

Pin a
shown in Fig. 19.
Pin b
Fig. 19
3 Apply grease to the bucket pin holes and the Detail G

Apply grease
connecting surfaces of the arm end and link (a total of
4 locations).
Apply grease
Fig. 20
101
Step 8 Lift
Installing the boom Wire rope
18 mmø × 3 000 mm
1 Cleaning boom 08
1 Clean holes a in the boom boss. Wire rope

2 Grease the holes a on completion of cleaning. 18 mmø × 10 000 mm
Chain block
2 Attaching wire ropes and chain block to boom 08
Wire rope
5 ton
18 mmø ×
1 Attach wire ropes chain block and shackles to the 12 000 mm
boom as indicated in Fig. 21. Wire rope
2 Lift the boom, keeping holes a level. 18 mmø × 3 000 mm
Protector
Note:
Level the boom by adjusting the preset chain blocks.
CAUTION: Boom 08
Under no circumstances should anyone enter
Protector a
underneath the lifted boom.
Boom weight:
Standard boom 7 090 kg (15 600 lb)
BE boom 7 200 kg (15 840 lb) Fig. 21
H boom 7 610 kg (16 740 lb) a
Long boom 8 020 kg (17 645 lb)
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. Lift
(0.7 inø) (390 in L)
Move
18 mmø × 12 000 mm (L) : 1 pc.
(0.7 inø) (468 in L)
Protector: 3 pcs.
Chain block (for 5 tonne load): 1 pc. a Cab
b
3 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. Rope
Notes:
i) Take care that the boom does not hit Fig. 22
the cab.
ii) Attach a rope to the boom end to guide Hold
it, as the lifted boom can sway
unexpectedly.
Rope: 1 pc.
8 mmø × 5 000 mm (L)
(0.3 inø) (197 in L)
b
4 Installing the boom a
1 Align the pin holes in the boom foot and main

frame.
2 Insert the pin at location a and b .
Note:
Grease the pin before insertion.
Fig. 23
102
Shim t = 1.0
3 Check the size of clearance a between the boom t = 2.3
Detail H
foot boss and boom.
Pin
If a is more than 3mm, fit the shim attached to
the pin, on the side nearest the cab.
Plate
Clearance a
Bolt, Boom foot boss
spring
washer Fig. 24
4 After installing the pin, use bolts and spring Washer spring
washers to fit a plate to the pin end. Plate Bolt
Note:
Apply lubricant to the bolts before installation.

(390 N·m/290 lbf·ft)
Fig. 25
5 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
6 Remove the wire ropes and chain blocks and

shackles attached to the boom.
Remove the wire ropes
Fig. 27
103
Step 9
Connecting the hoses between the base machine and boom
1 Connecting the hoses Cylinder hose a
Note: ※
1 Remove the caps from the piping ports and hoses.

Boom connection
CAUTION:
2 Connect the 4 hoses a base machine to the

boom. Cylinder hose a Fig. 28
3 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
2 After connecting the hoses, clean away any residue oil
travel device at with the boom cylinders fully from the outside of all parts.
extended. Perform an operational check in
accordance with the instructions given on page
109.
Tightening torque: 1-1/2 hoses: 21 kgf·m

(205 N·m/150 lbf·ft) Detail I
1-1/4 hoses: 14 kgf·m Pin
(140 N·m/100 lbf·ft)
Notes:
ii) Connect the hoses so as not to contact other
parts.
seat faces of the hoses. Fig. 29
of the hoses.
4508805) to install the hoses. Apply a thin layer
installation.
Step 10 Do not pull the

Connecting the boom cylinder rods pins right out
1 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.
cylinder connection pins and pin holes.
Fig. 30
3 Apply grease to the pins and pin holes.
104
Hold
2 Connecting each boom cylinder rod
1 Attach wire ropes to the boom cylinder and lift it.
Wire rope: 1 pc. Plate

10 mmø × 3 000 mm (L) Spring
(0.4 inø) (117 in L) washer
Bolt
Scaffolding: 2 pcs.
Note:
Make sure to use scaffolding to align the pin holes
Scaffolding
and insert the pins.
A leader should be decided upon to direct the
Fig. 31
operation of both the base machine and the crane.
Wire rope
2 Start the engine and perform a boom raise 10 mm ø × 3 000 mm
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.
Note:

(390 N·m/290 lbf·ft)
Fig. 32
Detail J Bolt,
spring Plate
Pin washer
Fig. 33
Fig. 35
3 Install the cylinder rod for the opposite side in the same
manner.
Fig. 34
105
Step 11
Connecting the boom cylinder grease hoses and electrical

wiring
1 Connecting the boom cylinder grease hoses
1 Attach the boom cylinder grease hose to the rod

as indicated in Fig. 36.

(60 N·m/45 lbf·ft)
Grease hose
Notes:
i) Make sure not to twist the hoses during
installation as doing so can shorten their service Fig. 36
life.
Detail K
ii) Install the hoses such that they do not contact
other parts. Electric wire
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. Connect
2 Attach the grease hose for the opposite side in the

same manner.
3 After connecting the grease hoses, clean away Fig. 37
any residue grease from the outside of all parts.
2 Connecting the electrical wiring at the boom bottom Arm cylinder

Connect the electrical wiring for the head lights as
Note:
3 Remove the lever blocks used to fix the arm cylinder in

"Step 5- 2 " on page 98. (See Figs. 38 and 39)
Fig. 38
Detail L
Wire rope
Lever block
Wire rope
Fig. 39
106
Step 12 Detail M
Greasing (2)
a
1 The machine is provided with a pneumatically operated
grease gun.
b
automatically.
(4) Connect grease gun b to the desired grease
IMPORTANT:
Run the engine at medium speed or more when c Fig. 40
2 Start the engine.
3 1 Supply grease to 2 points as shown in Figs. 41

and 42.
2 Supply grease to 4 points as shown in Figs. 43
and 44.
Notes: Fig. 41

speed above medium speed. Detail N
with a standard air grease gun. Grease up at the
iii) Insufficient greasing will wear the pins.
BOOM CYL. BOTTOM BOOM CYL. BOTTOM
Fig. 42
Detail O
Fig. 43 BOOM CYL. ROD

BOOM FOOT
Fig. 44
107

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
f
b

at this time.
g
Note:
hose.
h
Fig. 47
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. 48
Detail P
Problem
area
※
Fig. 49
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
Lower
the arm cylinder back onto the block.
Block a
Fig. 50
109
Step 15
Air bleeding of boom and arm cylinder
Raise
Lower
CAUTION:
Make sure that nobody other than the operator is in or
on the hydraulic excavator.
2 Idle the engine sufficiently to release the air in the

hydraulic system.
3 Check for unusual vibration or noise.
4 Operate each cylinder a few times to bleed the air
in the hydraulic system, according to the following
procedure.
Note:
Fig. 51
The engine speed should be kept as low as
possible.
Retract
Extend
2 Procedure
Action Fig. 52
1 Start the engine.
Note:
Run the engine at low speed.
2 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.
4 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to next page)
110
3 Bleeding locations
CAUTION:
Take all reasonable precautions as this work is to be conducted high above the ground.
4 1 Set the front-end attachment on the ground as illustrated below.
2 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. Arm cylinder Boom cylinder
4) Continue bleeding until only oil escapes.
5) Tighten the plug securely. Boom cylinder
6) Replace the rubber cap.
Arm cylinder
Fig. 53
Detail Q
Fig. 54
Detail R
5 Recheck the oil level in the hydraulic tank. If the oil

level is low, refill the tank. Level check
Fig. 55
111
Step 16
Installing the arm
1 Position the boom end about 3 500mm (135 in) above

the ground.
2 Preparing the arm connection pin for installation 3 500 mm

(135 in)
1 Pull arm connection pin a out from the boom end
boss before starting the work. Fig. 56
Notes: Pin a
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 Clean away the anti-corrosive applied to the arm

connection pin a .
3 Apply grease to the pin and pin holes.
3 Attaching wire ropes to the arm

Fig. 57
1 Remove pin b attached to arm 09 . Hold
2 Grease the pin and pin holes.
3 Attach wire ropes, chain blocks and shackles to
the arm and lift it as indicated in Fig. 58. Wire rope
Wire rope
14 mmø × 3 000 mm 14 mmø × 10 000 mm
Arm weight:
BE arm 4 350 kg (9 570 lb)
Long arm 3 990 kg (8 780 lb) Shackle
Chain block
Standard arm 3 590 kg (7 900 lb) 2.5 ton
H arm 4 010 kg (8 820 lb) b
Semi-long arm 3 900 kg (8 580 lb)
Wire ropes: 4 pcs.

Wire rope
14 mmø × 10 000 mm (L) : 2 pcs. 14 mmø × 3 000 mm
(0.55 inø) (390 in L)
14 mmø × 3 000 mm (L) : 4 pcs. c
(0.55 inø) (117 in L)
Shackle (for 2.5 tonne load): 4 pcs. Shackle
Chain block (for 2.5 tonne load): 2 pcs.
Arm 09
4 Lift the arm, keeping holes c level.
Fig. 58
Lift
Note:
Level the arm by adjusting the preset chain blocks.
CAUTION:
Under no circumstances should anyone enter
underneath the lifted arm.
c
Fig. 59
112
4 Moving the arm toward the boom Lift
Move
1 Position 2 sets of scaffolding a as indicated in

Fig. 60.
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. 3 000 mm

(117 in)
8 mmø × 5 000 mm (L) a Scaffolding
Rope
(0.3 inø) (197 in L)
Fig. 60
2 Slowly move the arm toward pin holes b in the
Hold
boom.
3 Align the pin holes b from up on the scaffolding,
in preparation to insert the pin.
All subsequent work should performed from the
scaffolding.
b
4 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.
Note: Fig. 61
Exercise due caution in handling the pin as it is

extremely heavy. Hold
Pin weight: 96 kg (210 lb)
CAUTION:
Exercise due caution to avoid falling from the
scaffolding.
Pin
Plate
Spring
5 Install the stopper. washer
So as to prevent the pin from become removed, Bolt
use 2 bolts and spring washers, and 1 plate to
install a plate over the pin end.
Fig. 62
Note:
Apply lubricant to the bolts before installation. Detail S Thrust plate Plate
t = 2.0 c
t = 1.0 d
Tightening torque: 40 kgf·m Pin
(390 N·m/290 lbf·ft)
Bolt,
spring
washer
Fig. 63
113
6 Position a wooden block under the arm end and
slowly lower the arm to the ground.
Remove the wire ropes and
chain blocks and shackles
Wooden block: 1 pc. attached to the arm.
100 mm (L) × 750 mm (W) × 50 mm (H) Lower
(4 in) (30 in) (2 in)
7 Remove the wire ropes and chain blocks and

shackles attached to the arm.
Wooden block
Fig. 64
Step 17
Lift
Installing the arm cylinder
Wire rope
10 mmø × 3 000 mm Arm cylinder
1 Attaching wire rope to the arm cylinder
1 Lift the arm cylinder with a crane.
Wire rope:
10 mmø × 3 000 mm (L) : 1 pc.
(0.4 inø) (117 in L)
2 Gradually lift the arm cylinder such that the height

of the arm cylinder and arm bracket pin holes
coincide.
Fig. 65
3 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 Arm cylinder

pin hole
2 Inserting the pin
1 Grease the pin before insertion.

2 Insert the pin.
Fig. 66
114
3 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
(390 N·m/290 lbf·ft) Bolt
Fig. 67
CAUTION:
Exercise due caution to avoid falling from the
scaffolding. Detail T
Pin
Plate
Bolt,
spring
washer
Fig. 68
Step 18
Connecting the arm cylinder grease hose
1 Attach the arm cylinder grease hose to the rod as

indicated in Figs. 69 and 70.
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 Fig. 69

(60 N·m/45 lbf·ft)
Notes: Detail U
Grease hose
installation as doing so can shorten their service
Avoid contact here
life.
other parts.
during installation.
2 After connecting the grease hose, clean away any

residue grease from the outside of all parts.
Fig. 70
115
Step 19
Connecting the bucket cylinder hoses and grease hoses
Note:
Bucket cylinder
Bucket cylinder hose

1 1 Remove the caps from the bucket cylinder hoses.
11
CAUTION:
2 Connect hoses 11 between the boom and bucket

cylinder. Fig. 71

(140 N·m/100 lbf·ft)
Notes:
ii) Connect the hoses so as not to contact parts.
of the hoses.
v) Use O-rings 12 (P/No. 4508805) to install the
hoses. Apply a thin layer of sealant #98D to the
O-rings before installation. Wire rope
Lever block
3 Install the bucket cylinder hose for the opposite
side in the same manner.
Wire rope
2 After connecting the hoses, clean away any residue oil

3 Removing the wire ropes and lever block used to

fasten the bucket cylinder rod in "Step 6- 4 on page
100.
Fig. 72
116
4 Connect grease hoses at part a indicated by . Detail V

(60 N·m/45 lbf·ft)
Notes:
ii) Connect the hoses so as not to contact parts.
iv) Pay attention not to damage the joining surfaces Fig. 73
of the hoses.
5 After connecting the grease hose, clean away any

residue grease from the outside of all parts.
Fig. 74
117
Step 20 Detail W
Greasing (3)
a
grease gun.
hose length is obtained; the hose will be locked b
automatically.
IMPORTANT:
2 Start the engine.
3 1 Supply grease to 1 point as shown in Figs. 76 and

77.
2 Supply grease to 4 points as shown in Fig. 78.
Fig. 76
Notes: Detail X
ARM CYL. BOTTOM
Fig. 77
Detail Y
BOOM AND ARM JOINT

ARM CYL. ROD
BUCKET CYL. BOTTOM
Fig. 78
118

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
f
b

at this time.
g
Note:
hose.
h
Fig. 81
119
Step 21
Air bleeding of arm and bucket cylinder
Roll out
Retract
Roll in
Extend
CAUTION:
Make sure that nobody other than the operator is in or
2 Idle the engine sufficiently to release the air in the Fig. 82

hydraulic system.
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
120
3 Bleeding locations
CAUTION:
4 1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION:
Arm cyl.
Arm cyl.
2) Loosen the plug.
3) A mixture of air and hydraulic air will escape
from the bleeder. Bucket cyl.
5) Tighten the plug securely.
Bucket cyl.
Fig. 83
Detail Z
Fig. 84
Detail A
5 Recheck the oil level in the hydraulic tank. If the oil

level is low, refill the tank. Level check
Fig. 85
121
Step 22
Bucket installation
1 Preparing the bucket for installation
1 Apply grease to pin holes a and b .

2 Apply grease to pins c and d . a
c
d
Fig. 86
Lift
2 Attaching wire ropes to the bucket
1 Attach wire ropes and chain block to bucket 10 as Wire rope

indicated in Fig. 87. 14 mmø × 3 000 mm
Notes:
Wire rope
i) Attach protectors to positions a (see Fig. 87) to Chain block 14 mmø × 10 000 mm
avoid damaging the bucket. 2 ton
Wire rope
ii) Level the bucket by adjusting the preset chain
14 mmø × 3 000 mm a
blocks.
a
CAUTION: b
lifted bucket.
b
2 Lift the bucket, keeping holes b level.
Bucket weight: 1.8 m3 1 870 kg (4 115 lb)

2.0 m3 2 060 kg (4 530 lb)
2.4 m3 2 350 kg (5 170 lb)
2.8 m3 2 400 kg (5 280 lb) Bucket 10
2.9 m3 2 500 kg (5 500 lb)
3.4 m3 2 650 kg (5 830 lb) Fig. 87
4.3 m3 BE 3 580 kg (7 875 lb)
3.4 m3 ROCK 3 460 kg (7 610 lb)
3.6 m3 BE-H ROCK 3 490 kg (7 680 lb)
4.3 m3 BE-ROCK 4 100 kg (9 020 lb)
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.
122
3 Position the arm end around 2 500mm (98 in) above
the ground.
2 500 mm
(98in)
Fig. 88
Lift
4 Moving the bucket to the arm
Move
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.
2 Move the bucket to pin holes d .
d
Fig. 89
123
Hold
5 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 Align the pin holes in preparation for inserting the

pins. Bolt
Spring
2 Insert the pin. washer
Insert thrust plates 14 and 16 between the bucket Stopper
and the arm to adjust the clearance. Pin
Notes:
i) Apply grease to the pins before insertion.
ii) Refer to the following page for details of the
thrust plate adjustment procedure. Fig. 90
3 Install the stopper using bolts and spring washers. Detail B Stopper
Bolt,
spring
Note: washer

(390 N·m/290 lbf·ft)
Pin Fig. 91
Note:
Make sure to adjust clearance (a) to bring it into the
range 1 to 2mm. Detail C
O-ring 15
Arm
6 1 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
Thrust plate
boss of the arm. 14 and/or 16
(a) Fig. 92
2 Tighten the nuts of O-rings 15 .
Tightening torque: 0.6 kgf·m Detail D

(6 N·m/4.3 lbf·ft)
Note:
Detail E 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. 93
Assemble the O-ring so 15
that no gap is left here.
Fig. 94
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 Park the machine on a level surface. Lower the bucket to the ground with the flat side down so the bucket will not
roll.
2 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.
3 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 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.
5 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).
6 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 F
Location of clearance
adjustment
d c c b
Arm Pin
Groove width (D)
Bucket a
Clearance (A) Clearance (C)
Clearance (B)
Bucket
Fig. 95
125
Extend the bucket cylinder
8 Adjusting the arm angle
1 Set the arm angle to

between 120° to 140°.
2 Extend the bucket
cylinder such that pin
hole a of the bucket link 0˚
14
aligns with pin hole b of to
20˚
the bucket. 1
9 Connecting the bucket and link
1 Carefully align the link

and bucket pin holes. a
2 Insert the pin. b a b
Note:
3 To prevent the pin from becoming removed, install Fig. 96 Fig. 97
stopper over the pin ends using bolts and spring
washers.
Note:
(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. Bolt
5 Tighten the nut on O-ring 15 . Spring washer
Stopper
Tightening torque: 0.6 kgf·m
(6 N·m/4.3 lbf·ft)
Detail I
Pin Fig. 98
O-ring 15 Detail G
Bolt,
spring
Pin washer
Fig. 101
Note:
Detail J The longer bolt makes the O-ring Fig. 99
easier to assemble. After assembly, cut
it into ☆ 10~20 mm length.
(Bolt size: M5) Detail H
☆ 10 ~ 20 ☆ 10 ~ 20 Link
Slit O-ring 15
Double nut Double nut Bucket
Assemble the O-ring so 15

that no gap is left here.
Fig. 102
Fig. 100
126
Step 23
a
Reinstall the handrail and adjusting the rearview mirror
1 Reinstalling the removed handrail
Reinstall the handrail a removed on page 75 of the

base machine assembly instructions.

(90 N·m/65 lbf·ft)
Notes:
Fig. 103
i) Apply lubricant to the threads of the mounting
bolts.
ii) Hand screw in all bolts first, before tightening to Rear view mirror Rear view mirror
2 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.

(10 N·m/7.2 lbf·ft)
Fig. 104
Step 24
Installing the lamp
1 Put bracket-fitted lamps 17 on the right and left Detail K

side of the boom. 17

(50 N·m/35 lbf·ft)
2 Connect the electric wire couplers a and b . 17
Note:
anti-corrosive and any rust from the couplers. a b
Fig. 105
127
Step 25 Detail L
Greasing (4)
a
grease gun.
automatically.
IMPORTANT:
Note:
Cap Head
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 g
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 Grease Cavity
g direction until it bottoms or tap using screw driver Fitting f
grip. Cap e
Pin Screw
Driver
Fig. 107
2 Start the engine.
3 Supply grease to 9 points as shown in Fig. 108. Detail M
Notes:
Fig. 108
128
d
(1) Turn power switch d ON to activate the pump. e
Grease is sucked up and supplied to high-pressure
grease gun b .
IMPORTANT:
a
grease. Securely close check valve cock e when all
air-mixed grease is bled out. Fig. 109
(2) Grab high-pressure grease gun b and pay out the



IMPORTANT:
g
f
b

switch d OFF, then pull grease gun b lever to c Fig. 110
pump a , and the hose so as to ensure long life of
the components. A little grease will be discharged g
at this time.
Note:
hose.
h Fig. 111
5 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
Arm
roll-in Boom lower
CAUTION: Bucket
roll-out Bucket roll-in
Make sure that nobody other than the
operator is in or on the hydraulic
excavator.
Fig. 1
hydraulic system.
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
130
Step 2
Bleeding locations
CAUTION:
As this work is to be conducted at a height, take due safety precautions.
1 1 Set the front-end attachment on the ground in the position illustrated below (Fig. 2).
2 Stop the engine.
CAUTION:
3 Following the procedure outlined below, release the air from the cylinders, by way of the bleeding
locations indicated by .
2) Loosen the plug.
3) Air and hydraulic oil will escape together.
5) Tighten the plug securely to its original position.
Arm cylinder Arm cylinder
rod bottom
Bucket cylinder
bottom
Boom cylinder
Bucket cylinder rod
rod
Boom cylinder
bottom
Fig. 2
Detail A
Level check
2 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. 3
Fig. 4 when checking the oil level.
Fig. 4
131
7-4 Adjusting the track link tension
1 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. 90° ~ 110°
2 Place wooden blocks under the main frame to

support the machine, as indicated in Fig. 1.
1 200 mm (L) × 800 mm (W) × 1 000 mm (H) Fig. 1
Wooden block
(47 in) (31 in) (39 in)
3 Rotate the uplifted track link forwards through 2

turns, and then backwards through 2 turns. Detail A
2 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) 460 ~ 510 mm Fig. 2

Standard tension (18 ~ 20 in)
3 To loosen the track link tension, slowly loosen valve a Detail B

(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)
CAUTION:
Over-loosening valve a or loosening the valve over-
abruptly can cause the valve to fly off the machine or
pressurized grease to shoot from the valve, due to the
Fig. 3
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
Detail C
circumstances should grease fitting b be loosened.
a
4 Adjusting the track link tension b
1 If the track link tension is outside the range of the
standard tension, tighten or loosen the track link
appropriately (see the next page).
2 After adjusting both the left and right track links,
equalize the left and right track link tensions by
driving the machine forward and backward. Grease outlet
3 Recheck the track link tension. If the tension is
outside the range of the standard value, readjust
Fig. 4
the track links.
132
Detail D
Loosen the Track
b a
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 Fig. 5
and track links, remove it before loosening.
1 To loosen the track, slowly turn valve a b a

counterclockwise using long socket 24; grease
will escape from the grease outlet.
2 Between 1 to 1.5 turns of valve a is sufficient

to loosen the track.
3 If grease does not drain smoothly, slowly rotate

the raised track. Grease Outlet
4 When the proper track sag is obtained, turn

Fig. 6
valve a clockwise and tighten to 15 kgf·m (150
N·m/110 lbf·ft).
Detail E
Tighten the Track
CAUTION:
b a
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
Fig. 7
specifications.
133
7-5 Final trial operation check
Step 1
After check
Detail A
1 After connecting all the hoses, check that no hose hits

against other hose or parts.
2 1 Adjust the track link tension appropriately. (See

pages 132 and 133 "Adjustment of track link
tension".)
2 Check all functions of the machine. (See "Checks

after completing the assembly")
3 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
1 Thoroughly clean any oil from the machine with

rags. Detail B
2 On full completion of the backhoe assembly, recheck

that all bolts are tightened to the specified torque.
Fig. 3
134
7-6 Backhoe lubrication
1 Lubrication
Lubricating points and grease types
1 After assembling the backhoe front-end, lubricate

the points illustrated in Fig. 1.
b b
2 Select an appropriate grease type according to

the following table.
Brand Name of Recommended Grease Fig. 1
Application Bucket, Arm and Boom, Swing

Gear, Swing Bearing, etc.
Air
Manufacturer Temp.
− 20 to 40°C (− 4 to 104°F)
Hitachi Genuine Doubrex HK

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 2

EP Grease
Note: Locations requiring lubrication No.

On shipment from the factory, the machine is filled
a Front joint pins
with the lubricant marked . 9
(around bucket)
b Front joint pins
11
(other than around bucket)
135
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 d
performed at height. Take appropriate measures to
avoid falling from the machine.
e
Note:
Set the engine to run at medium idle or higher when
using the lubricator.
3 Lubricator Operation
1 Turn power switch d ON to activate the pump.

Grease is sucked up and supplied to high- Fig. 2
pressure grease gun b .
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 Hold high-pressure grease gun b and pay out the

3 Press hydro-chuck g protruding from high-
pressure grease gun b into the grease nipple,
and pull the lever to discharge grease.
4 Release the lever when greasing is complete;
g
f
CAUTION:
When detaching hydro-chuck g from grease nipple h , b
grease nipple h tip may break unless special care is
taken, as follows:
• Tilt nozzle f a little so as to release the connecting
• Slowly detach hydro-chuck g from nipple h .
Fig. 3
5 When all greasing work is complete, turn power c
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. g
Note:
inspect the hose for cracks, grease leakage, or any h
other damage. If any damage is found, replace the Fig. 4
hose.
136
NOTES
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137
NOTES
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138
MOUNTING PROCEDURE FOR

FRONT-END ATTACHMENTS
ATTACHMENTS
LOADER FRONT
8. Loader front mounting procedure
8-1 Preparation
Loader front assembly flowchart
Fig. 1
Step 1
Parts required
Item
No. Shipping
Part List
00 (22) 4331075 CYL., BOOM (R) 1
01 (23) 4331076 CYL., BOOM (L) 1
02 (25) 4089703 FLANGE; SPLIT 8 Boom cyl.
03 (26) M341445 BOLT; SOCKET 16
04 (28) 4450978 HOSE 2 Boom cyl. rod
05 (29) 4414282 HOSE 2 Boom cyl. bottom
06 (30) 4508805 O-RING 6 Boom cyl. bottom + rod
07 (31) 4187328 O-RING 2 Boom cyl. rod
( )
141
Item
No. Shipping
Part List
08 (00) ——— BOOM/ARM LINKAGE 1 Includes boom, arm, arm cylinder, level cylinder, tilt cylinder, and links A&B
09 (02) ——— BUCKET, LOADER 1 4.0 Bucket
10 (04) ——— LAMP ASS’Y 2 For the front-end (with mounting bolts)
11 (06) 4405604 HOSE 2 1" Base machine-front end
12 (07) Z966993 O-RING 4 1"
13 (09) 4318402 HOSE 2 1"-1/4" Base machine-front end
14 (10) 4508805 O-RING 4 1"-1/4"
15 (12) 4508805 O-RING 12 1"-1/4"
16 (13) 4421535 HOSE 2 1"-1/4" Front end-bucket
17 (14) 4162704 O-RING 2 Arm end
18 (15) 4102702 RING 2 Arm end
19 (17) Z425176 CORK 2 For plugging the eye bolt mounting hole in the tilt cylinder
20 (19) 3096646 CLAMP, HOSE 2 For hoses between the base machine and boom
21 (20) 3074182 CLAMP 4 For hoses between the boom and arm
22 (21) J901211 BOLT 9 For securing the clamps
23 (22) J950012 NUT 18
24 (23) Z449490 WASHER 18
25 (25) 4441974 HOSE 6 For boom to arm
26 (26) 4508805 O-RING 12
( )
142
8-2 Mounting the loader front
Step 1
Note: Do not completely detach the pin
Preparing the base machine
1 Preparing the base machine
1 Remove the boom foot pin fitted to the base

machine.
Notes:
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.
Fig. 1
foot pin and pin holes.
3 Apply grease to the boom foot pin and pin holes. Lift
Step 2
Wire rope
Installing the boom cylinders 12 mmø × 5 000 mm
1 Attaching wire ropes to the boom cylinders
1 Attach wire ropes to boom cylinder (L) 01 as

Boom cylinder weight: 700 kg (1 540 lb)
Wire ropes:
12 mm × 5 000 mm (L) : 2 pcs.
(0.45 in) (195 in L)
01 a
2 Clean away the anti-corrosive applied to bottom
and rod boss a and b of the boom cylinder.
3 Apply grease to boss a and b .
2 1 Lifting boom cylinder 01 Fig. 2

2 Lift the boom cylinder, keeping it level.
b
Note: Hydraulic
piping
The left and right boom cylinders differ in the Right boom cylinder 00
manner depicted in Fig. 3. Be sure not to mix them
up.
Left boom cylinder 01 Fig. 3
143
3 Preparing the boom cylinder foot pins for installation
1 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 inside-
facing bracket.
ii) Shims are attached to foot pins a and b , which
are to be used during pin installation. a
b
Fig. 4
foot pins and pin holes.
Hold
3 Apply grease to the boom foot pins and pin holes.
4 Installing boom cylinder (L) 01 Move
1 Move the boom cylinder toward the base machine,

such that the bottom boss of the boom cylinder Bolt
Spring washer
aligns with the frame boss.
Plate
Note: b
Install the boom cylinder such that the hydraulic
piping faces downward.
2 Align the pin holes of the boom cylinder and base

machine. 01
Install the boom cylinder
3 Check the size of clearance c . with the hydraulic piping
If c is more than 4mm, fit the shim attached to facing downward.
the pin, on the side away from the pin head.
Fig. 5
4 Insert pin b , being careful not to damage the seal
on the cylinder. Detail A
Shim Pin
5 Fit and tighten the plate with bolts and spring
washers.
Plate
Note:
Apply lubricant to the pin before installation. Clearance
Bolt, c
Cab side
spring washer
(390 N·m/290 lbf·ft)
5 Lower the boom cylinder onto a cylinder support such

that it is maintained level. Install boom cylinder 00 in 00
the same manner as described above.
Note:
Place a V-block shaped rest under the top of the 01
boom cylinders to protect the hydraulic piping.
V-block
Cylinder support: 1 pc.
Height: 1 800 mm (70 in) Cylinder support
V-block: 2 pcs.
Fig. 7
144
Step 3 Boom
Boom cylinder bottom hoses
Connecting the boom cylinder hoses cylinder rod hoses 04 (Out side)
(In side) 05
1 Connecting the boom cylinder hoses
Note:
CAUTION:
2 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.
(140 N·m/100 lbf·ft)
Notes:
with other parts.
of the hoses.
4187328) to install the hoses. Apply a thin layer 2 After connecting the hoses, clean away any residue oil
installation.
Step 4
Bleeding the boom cylinders
1 Bleeding the boom cylinders

Start the engine and set it to run at low idle. Slowly Boom cylinder
extend the boom cylinders to bleed any air trapped

inside, repeating the process until the cylinder rods
extend at constant speed.
Notes:
i) Avoid operating the cylinders jerkily, rapidly or in
seals. Fig. 9
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.
2 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
1 1 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)
Fig. 11
(20 in) (20 in) (20 in)
08
2 Clean the pin holes a of the boom foot indicated b
by .
3 Clean the pins b for the boom cylinder indicated a
by .
Fig. 10
Wooden block
2 Installing hoses to boom linkage.
Hose 25
CAUTION:
after confirming that all pressure has been released. 08
2 Connect the 6 hoses 25 between the arm and

boom. (See Figs. 12 and 13)

(140 N·m/100 lbf·ft)
Fig. 12
Notes:
Detail C
21 22 23 24
with other parts.
25 700 mm (27 in)
of the hoses.
O-rings before installation.
700 mm
(27 in)
3 Fit clamps 21 to the hoses, using bolts 22 , nuts 23
and washers 24 , as indicated in Fig. 13.
Fig. 13
(90 N·m/65 lbf·ft)
3 After connecting the hoses, clean away any residue oil.
146
Step 6
Preparation of the loader bucket
1 1 Position loader bucket 09 as indicated in Fig. 14.
Bucket assembly weight:

3.6 m3 Bottom dump bucket 6 080 kg (13 380 lb)
4.0 m3 Bottom dump bucket 5 620 kg (12 365 lb) a
09
4.0 m3 Tilt dump bucket 4 980 kg (10 960 lb)
4.4 m3 Tilt dump bucket 4 630 kg (10 190 lb)
b
2 Clean pins a and b in bucket 09 .
3 Extract pins a and b from the bucket.
4 Clean pin holes a and b on the bucket.
Fig. 14
09
2 1 Remove cover c as shown in Fig. 15.
Fig. 15
2 Set pins d and e , previously removed from the View D

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

Fig. 16 and 17. d
O-ring 17
Ring 18
Bucket
e
Fig. 16
Fig. 17
View E
4 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. f
Fig. 18
147
3 Remove urethane foam sleeves a , fitted as protection
on the plated dump cylinder rod.
Detail F Dump cylinder
Urethane
foam sleeve a
Plated Dump cylinder

cylinder rod Fig. 19
Fig. 20
148
Step 7 Lift
Wire rope
Installing the boom 26 mm × 3 000 mm
1 Attaching wire ropes to the boom
1 Attach wire ropes and chain block to boom 08 as Chain block

indicated in Fig. 21. 6 ton Wire rope
26 mm ×
10 000 mm
Loader boom weight: 11 100 kg Wire rope
(24 420 lb) 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
Chain block (for 6 tonne load): 1 pc. 08
2 Lift the boom, keeping holes a level. a
Note:
Level the boom by adjusting the preset chain blocks. Fig. 21
a
CAUTION:
Under no circumstances should anyone enter the area
beneath the lifted boom. Lift
Move
2 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: a 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 b
lifted boom can sway unexpectedly.
Rope
Rope: 1 pc.
8 mmø × 5 000 mm (L) Fig. 22
(0.3 inø) (197 in L)
Hold
3 Installing the boom
1 Align the pin holes in the boom foot and main

frame.
2 Insert the pin at location a and b .
b
a
Note:
Fig. 23
149
Shim t = 1.0
t = 2.3
3 Check the size of clearance a between the boom Detail G
foot boss and boom. Pin
If a is more than 3mm (0.1 in), fit the shim
attached to the pin, on the side nearest the cab.
Plate
Clearance a
Bolt,
spring
washer Fig. 24
4 After installing the pin, use bolts and spring Spring washer
washers to fit a plate to the pin end.
Plate Bolt
Note:

(390 N·m/290 lbf·ft)
Fig. 25
5 Place a wooden block at the top of the boom, and Lower

lower the boom onto the wooden block.
Wooden block: 1 pc.

100 mm (L) × 750 mm (W) × 50 mm (H)
(4 in) (30 in) (2 in)
Wooden block
Fig. 26
6 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:
1 Connecting the hoses
1 Remove the caps from the travel motor ports and Fig. 28
travel hoses.
CAUTION:
Detail H
2 Connect the 4 hoses 11 and 13 between the base

11
machine and the boom.
Tightening torque: 14 kgf·m 13

(140 N·m/100 lbf·ft)
Notes:
with other parts.
seat faces of the hoses. Fig. 29
of the hoses.
v) Use O-rings 12 (P/No. Z966993) and 14 (P/No.
4508805) to install the hoses. Apply a thin layer Detail I
installation.
20 22 23 24
2 Fit clamps 20 to the hoses, using bolts 22 , nuts 23 and
washers 24 , as indicated in Fig. 30.

(90 N·m/65 lbf·ft)
Fig. 30
151
Detail J
Step 9 Pin
Connecting the boom cylinder rods
1 Preparing the boom cylinder connection pins for boom

cylinder connection
Fig. 31
1 Pull the boom cylinder connection pins out from
Do not
the boom before starting the work.
completely
remove the pins
Note:
Do not completely remove the pins, but leave the
pin end attached to the outer edge of the bracket.

cylinder connection pins and pin holes.
3 Apply grease to the pins and pin holes.
2 Connecting each boom cylinder rod

Lift
Fig. 32
1 Attach wire ropes to the boom cylinder and lift it.
Wire rope
Wire rope: 1 pc. 10 mmø × 3 000 mm
10 mmø × 3 000 mm (L)
(0.4 inø) (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.
Scaffolding Fig. 33
2 Start the engine and perform a boom raise

Pin Lift
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
washers. Spring
washer
Bolt
Note:

(390 N·m/290 lbf·ft)
Fig. 34
3 Install the cylinder rod for the opposite side in the same Detail K Bolt,
manner.
spring Plate
Pin washer
Fig. 35
152
Step 10
Connecting the boom cylinder grease hoses and electrical wiring
1 Connecting the boom cylinder grease hoses
1 Attach the boom cylinder grease hose to the rod

as indicated in Fig. 36.

(60 N·m/45 lbf·ft)
Grease hose
Notes:
installation as doing so can shorten their service
Fig. 36
life.
other parts.
2 Attach the grease hose for the opposite side in the

same manner.
3 After connecting the grease hoses, clean away
any residue grease from the outside of all parts.
Fig. 37
2 Connecting the electrical wiring at the boom bottom

Detail L
Connect the electrical wiring for the head lights as
Electric wire
Note:
Before connecting the electric wires, remove the Connect
Fig. 38
153
Step 11
Preparing for bucket installation

Level cylinder
1 Remove stopper a attached to the level cylinder

before shipment.
CAUTION:
a
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
c
b
2 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) Detail N
Holt
Arm
2 Remove shackles d and eye bolts e , used to
d
secure the bucket cylinders to the arm.
Detail N'
3 Lower the crane that is holding the tilt cylinders as e
Arm
outlined in step 1 , as shown in Fig. 42.
Lower
4 Fit corks 19 (P/No. Z425176) to the tilt cylinders to
plug the eye bolt e mounting holes.
Tilt cylinder
Fig. 41
e
5 Hold links b with a crane (Fig. 40).
6 Remove wire c used to fasten the links b and tilt
cylindes at the time of shipping.
Fig. 42
7 Remove the crane that is holding links b .
Note:
Store stopper a , wire ropes c , shackles d and CAUTION
eye bolts e away in a safe place, as they will be
required during subsequent transportation of the
machine.
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 Arm
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. Tilt cylinder
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.
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 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
seals.
Note: Tilt cylinder
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 Fig. 50
the cylinders and cylinder links, potentially leading to
damage to that cylinder.
CAUTION:
machine.
Fig. 51
156
Step 13 Detail P
Greasing (2)
a

grease gun.
automatically.
IMPORTANT:
2 Start the engine.
3 1 Supply grease 8 to points as shown in Figs. 53

and 54.
2 Supply grease 2 to points as shown in Figs. 55
and 56.
Fig. 53
Notes:
i) When using a lubricator, increase the engine Detail Q
Fig. 54
Detail R
Fig. 56
Fig. 55
157
4 Lubrication mouthed

grease gun b . e
IMPORTANT:
a


IMPORTANT:
g
f
b

at this time.
g
Note:
hose.
h
Fig. 59
158
Step 14
Installing the bucket
1 Preparing bucket 09 for installation
1 Apply grease to pin holes a , b , c and d .

2 Apply grease to pins c and d .
09
b
a
c Fig. 60
2 Check 2 O-rings 17 and 2 rings 18 to the inside of the

boss (2 positions). S
Clean face ※ before installing the O-rings.
09
Fig. 61
Section S O-ring 17
Ring 18
Bucket
※ Clean this
face
Fig. 62
159
3 Attaching wire ropes to bucket 09 Detail T
Lift
Wire rope
1 Attach shackles to the bucket eye plates, and 18 mmø ×
attach wire ropes and a chain block to the bucket. 3 000 mm
Wire rope
2 Lift the bucket as indicated in Fig. 63. Chain 18 mmø ×
block 10 000 mm
6 ton
Bucket weight:
Bottom dump type rock bucket Wire rope Shackle
3.6 m3 : 6 080 kg 18 mmø ×
(13 380 lb) 3 000 mm
09
Bottom dump type general purpose bucket
4.0 m3 : 5 620 kg
(12 365 lb) Detail U
Tilt dump type rock bucket Lift
4.0 m3 : 4 980 kg
(10 960 lb)
Tilt dump type general purpose bucket
4.4 m3 : 4 630 kg
(10 190 lb)
Wire ropes: 3 pcs.

18 mmø × 10 000 mm (L) : 1 pc. Fig. 63
(0.7 inø) (390 in L)
18 mmø × 3 000 mm (L) : 2 pcs.
(0.7 inø) (117 in L)
Chain block (for 6 tonne load): 1 pc.
3 Lift the bucket, keeping pin holes a and b level.

a b
Note: Fig. 64
Level the bucket by adjusting the preset chain
blocks.
CAUTION:
lifted bucket.
4 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
5 Moving the bucket to the arm
1 Lift the bucket to a height such that pin holes d in

c
the arm end are level with pin holes c in the
bucket.
2 Move the bucket to pin holes d .
Fig. 66
160
Hold
6 Installing the bucket
1 Align pin holes a and b in preparation for

inserting the pins. a
b
Fig. 67
2 Insert the pins.
Note:
Apply grease to the pins before insertion.
Spring
washer
3 Install the stoppers using bolts and spring
washers.
Bolt
Note:
Apply lubricant to the bolts before installation. Stopper Fig. 68
Pin

(390 N·m/290 lbf·ft) Detail V
Pin Stopper
Bolt
Spring
washer
Fig. 69
7 Set O-rings 17 and rings 18 in the groove between the Detail W

bucket and the arm, as indicated in Fig. 70.
Arm
O-ring 17
Ring 18
Bucket
Fig. 70
161
Lift
8 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
2 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 .
b Tilt cylinder
a
Fig. 72
3 Insert the pins
Hold
Note:
Grease the pins before insertion.
4 To prevent the pins from becoming removed,

install stoppers over the pin ends using bolts and
spring washers.
Tightening torque: 40 kgf·m Bolt

(390 N·m/290 lbf·ft) Stopper
Spring
washer
Note: Pin
Apply lubricant to the bolts before installation. Fig. 73
Detail X
Bolt
Spring
washer
Pin Stopper
Fig. 74
162
Step 15
Installing the bucket open/close hoses

Detail Y
1 Stop the engine and move each operation lever back

and forward, left and right a few times to release any
residual pressure.
2 Install bucket open/close hoses.
1 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 .

(140 N·m/100 lbf·ft)
Notes:
their service life will be shortened. Bucket open/close hose 16
Fig. 75
with other parts.
of the hoses.
O-rings before installation.
4 Close the air release cock on the hydraulic tank.
163
Step 16 Detail Z
Fitting the grease hoses
1 Connect the grease hose to the arm end boss Grease

hose
1 Attach the grease hose as indicated in Fig. 76.

(60 N·m/45 lbf·ft)
Notes:
i) Make sure not to twist the hose during
installation as doing so can shorten its service
life.
Fig. 76
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
2 Connect the grease hose for the opposite side in

the same manner.
2 After connecting the grease hoses, clean away any

residue grease.
164
Step 17
a
Reinstall the handrail and adjusting the rear view mirror
1 Reinstalling the removed handrail
Reinstall the handrail a removed on page 73 of the

base machine assembly instructions.

(90 N·m/65 lbf·ft)
Notes:
i) Apply lubricant to the threads of the mounting Fig. 77
bolts.
the specified torque. Rear view mirror Rear view mirror
2 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 Detail A

10
side of the boom.

(50 N·m/35 lbf·ft)
10
2 Connect the electric wire couplers a and b .
Note: a
Fig. 79
165
Step 19 Detail B
Greasing (3)

a
grease gun.
automatically.
b
IMPORTANT:
2 Start the engine.
3 Supply grease to 6 points as shown in Figs. 81 and 82.
Notes:
speed above medium speed. Fig. 81
equipped, the ZX800/ZX850H comes equipped Detail C
Fig. 82
166
4 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
arrow "a" direction, and scoop out the cap by Grease
Cavity
Fitting
applying force in the arrow "b" direction.
When installing, push the cap by hand in the arrow Cap Screw
Pin
Driver
"c" direction until it bottoms or tap using screw driver
grip. Fig. 83
Detail D
Front Joint Pins (Loading Shovel) 4 Dump Cylinder Bottom 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
2 Bucket and Link Joint Pin

5 Dump Cylinder Rod Pin
Bucket Joint Pin
3 Bucket Cylinder Bottom Pin

Link Joint Pin
6 Link and Arm Joint Pin
Fig. 84 Fig. 85
167

grease gun b . e
IMPORTANT:
a


IMPORTANT:
g
f
b

Fig. 87
the components. A little grease will be discharged
at this time.
g
Note:
hose.
h
Fig. 88
168
Step 20
Checks
＊ 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:
machine.
Fig. 89
169
8-3 Bleeding the cylinders and checking the hydraulic system
Step 1
Boom raise
Bleeding the hydraulic cylinders Bucket Arm extend
tilt-in
CAUTION: Arm Boom

Make sure that nobody other than the operator is in or retract lower
Bucket tilt-out
Fig. 1
hydraulic system.
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
170
Step 2
Bleeding locations
CAUTION:
1 1 Set the front-end attachment on the ground as illustrated below (Fig. 2).
2 Stop the engine.
CAUTION:
2) Loosen the plug.
3) A mixture of air and hydraulic air will escape from the
bleeder.
5) Tighten the plug securely.
6) Replace the rubber cap. Level cylinder Boom cylinder
rod rod
Level cylinder
bottom Arm cylinder Boom cylinder
Tilt cylinder rod
bottom bottom
Tilt cylinder
bottom
Arm cylinder
rod
Fig. 2
Detail A
2 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 Level check
Fig. 4 when checking the oil level.
Fig. 3
Fig. 4
171
8-4 Adjusting the track link tension
1 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.
2 Place wooden blocks under the main frame to
support the machine, as indicated in Fig. 1. 90° ~ 110°
1 200 mm (L) × 800 mm (W) × 1 000 mm (H)
(47 in) (31 in) (39 in) Fig. 1
3 Rotate the uplifted track link forwards through 2 Wooden block
turns, and then backwards through 2 turns.
Detail A
2 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:
Remove any rocks and other debris caught in the L
sprockets.
(Length L) 460 ~ 510 mm

Fig. 2
Standard tension (18 ~ 20 in)
3 To loosen the track link tension, slowly loosen valve a

(24mm hex) to release excess grease. Detail B
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)
CAUTION:
Over-loosening valve a or loosening the valve over-
abruptly 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 Fig. 3
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. Detail C
4 Adjusting the track link tension a

b
1 If the track link tension is outside the range of the
standard tension, tighten or loosen the track link
appropriately (see the next page).
2 After adjusting both the left and right track links,
equalize the left and right track link tensions by
driving the machine forward and backward.
Grease outlet
3 Recheck the track link tension. If the tension is
outside the range of the standard value, readjust
Fig. 4
the track links.
172
Detail D
Loosen the Track
b a
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 Fig. 5
and track links, remove it before loosening.
1 To loosen the track, slowly turn valve a

counterclockwise using long socket 24; grease b a
will escape from the grease outlet.
2 Between 1 to 1.5 turns of valve a is sufficient

to loosen the track.
3 If grease does not drain smoothly, slowly rotate

the raised track.
Grease outlet
4 When the proper track sag is obtained, turn

valve a clockwise and tighten to 15 kgf·m (150 Fig. 6
N·m/110 lbf·ft).
Detail E
Tighten the Track
CAUTION:
b a
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
After check Detail A
1 After connecting all the hoses, check that no hose hits

against other hose or parts.
2 1 Adjust the track link tension to an appropriate

figure. (See pages 172 and 173, "Adjustment of
track link tension.")
2 Check all functions of the machine. (See "Checks

after completing the assembly.")
3 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
1 Thoroughly clean any oil from the machine with

waste cloths. Detail B
2 On full completion of the backhoe assembly, recheck

that all bolts are tightened to the specified torque.
Fig. 3
174
8-6 Loader lubrication
1 Lubrication
Lubricating points and grease types
1 After assembling the loader front-end, lubricate

the points illustrated in Fig. 1.
2 Select an appropriate grease type according

to the following table.
Brand Name of Recommended Grease

Fig. 1
Application Bucket, Arm and Boom, Swing
Gear, Swing Bearing, etc.
Air
Manufacturer Temp.
− 20 to 40°C (− 4 to 104°F)
Hitachi Genuine Doubrex HK

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 2

EP Grease
Locations requiring lubrication No.

Note:
a Front joint pins
On shipment from the factory, the machine is filled 16
(around bucket)
with the lubricant marked .
b Front joint pins
14
(other than around bucket)
175
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
Lubrication of the top of the boom and arm is d
performed at height. Take appropriate measures to
avoid falling from the machine.
Note: e
Set the engine to run at medium idle or higher when
using the lubricator.
3 Lubricator Operation
1 Turn power switch ON to activate the pump.

Grease is sucked up and supplied to high-
Fig. 2
pressure grease gun .
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 Hold high-pressure grease gun b and pay out the
3 Press hydro-chuck g protruding from high-
pressure grease gun b into the grease nipple,
and pull the lever to discharge grease.
4 Release the lever when greasing is complete;
CAUTION: g
f
grease nipple h tip may break unless special care is
taken, as follows: b
· Tilt nozzle f a little so as to release the connecting
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 Fig. 3
c
b , pump a , and the hose so as to ensure long
component life. A little grease will be discharged
at this time.
Note: g
hose.
h
Fig. 4
176
NOTES
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177
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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
2 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. 1
(2) Lever Block (JIS B8819 equivalent to L3.2T)
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 Used
block.
·
Check that there is no damage on the lever
(3) Power Boost Wrench (including accessories), 3

width across flats of the torque wrench: 55 mm
(4) Air Compressor (slide surface cleaning)
(5) Soft Protectors 2
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 1
9 Fig. 1
attachment, do not allow any personnel to enter
the vicinity of the machine.
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

90° ~ 110°
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 Fig. 2
frame 3 , the work may be interrupted and loose
mounting bolts 1 may result.
1. Remove side frame mounting bolts 1 (10 used, 5

bolts in two places) from the extending side frame.
2. Rotate the upper structure to the side of the
extending side frame until the front attachment
faces the side frame perpendicularly.
3. Set the arm and boom angle between 90° to 110°.
Then, lower the bucket bottom to the ground.
180
4. 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 4
each wire rope. Attach soft protectors 6 between
the side frame 3 corners and wire ropes 4 to 3
prevent damage to side frame 3 and wire ropes 6
4 .
5. 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
5 Fig. 3
wire ropes.
6. Retracting side frame (Track gauge)
Turn the boom mode switch OFF so that the
machine can be raised off the ground with front 6
attachment. 7
7. While lowering the boom, raise the extending side 8
frame approx. 50 mm above the ground. If the side
frame is raised too much, extending force
increases.
8. 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.
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. 5
Stop the work and check if the front and rear of the
6
side frame are equally extended or if the side frame is
raised to the proper height.
7
Take corrective measures as necessary.
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 3
tension force. Damage to the lever block or wire rope
may result, possibly causing severe personal injury.
9. 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 2
1
centers may not be correctly aligned. Re-align bolt
and screw hole centers by operating the lever
blocks.
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 re-
tightening (by hand) of bolts difficult. 5
Fig. 7
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 3
and wire ropes.
14. Tighten bolts 1 with the power boost wrench and Longer bolt
torque wrench to specification.

2
(2 800 N·m/2 065 lbf·ft)
IMPORTANT: 1
Be sure to apply a film of lubricant to the bolt threads.
15. Extend the side frame on the opposite side in the Longer bolt
Fig. 8
same procedure.
90 to 110° Hook the wire
16. When the loader front attachment is installed, hook rope to the tooth
the wire ropes to the teeth in the right and left
edges.
Wire rope
Raise the track slightly off the ground
Fig. 9
Torque
Model 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
182
3 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 3
air.
Required Tools:
Power Boost Wrench (including accessories)
1
Torque Wrench (width across flats: 55 mm)
Air Compressor (slide surface cleaning)
2
1. Remove eighteen mounting bolts 1 (11 used for Fig. 10
each side) from the retracting side frames.
machine can be raised off the ground with front
attachment. 90° ~ 110°
3. Raise track 6 to be retracted using the front 6
attachment, as illustrated.
Slowly rotate raised track 6 back and forth. The
approximately 15°
side frame will be retracted with its own weight and
stop when it comes into contact with guide 2 . Fig. 11
IMPORTANT:
Maintain a 90° to 110° angle; never make an acute 5
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.
4. Slowly lower track 6 to the ground. Tighten six

mounting bolts 5 (5 used for each side) to the
specification. 5
Fig. 12

(2 800 N·m/2 065 lbf·ft)
5. Retract the opposite side, following procedures 1

to 4 above.
183
4 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. 1
(2) Lever Block (JIS B8819 equivalent to L3.2T)
· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 Used
block.
·
Check that there is no damage on the lever
(3) Power Boost Wrench (including accessories), 3

width across flats of the torque wrench: 55 mm
(4) Air Compressor (slide surface cleaning)
(5) Soft Protectors 2
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 1
9 Fig. 13
attachment, do not allow any personnel to enter
the vicinity of the machine.
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. Remove side frame mounting bolts 1 (10 used, 5 Fig. 14

bolts in two places) from the extending side frame.
2. Rotate the upperstructure to the side of the
extending side frame until the front attachment
faces the side frame perpendicularly.
3. Set the arm and boom angle between 90° to 110°.
Then, lower the bucket bottom to the ground.
184
4. 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 4
each wire rope. Attach soft protectors 6 between
the side frame 3 corners and wire ropes 4 to 3
prevent damage to side frame 3 and wire ropes 6
4 .
5. 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
5 Fig. 15
wire ropes.
machine can be raised off the ground with front 6
attachment. 7
7. While lowering the boom, raise the extending side 8
frame approx. 50 mm above the ground. If the side
frame is raised too much, extending force
increases.
8. 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.
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. 5
Stop the work and check if the front and rear of the
5
side frame are equally extended or if the side frame is
raised to the proper height.
7
Take corrective measures as necessary.
8
Fig. 17
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 3
tension force. Damage to the lever block or wire rope
may result, possibly causing severe personal injury.
9. 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 2
1
centers may not be correctly aligned. Re-align bolt
and screw hole centers by operating the lever
blocks. 9
Fig. 18
185
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 re-
tightening (by hand) of bolts difficult. 5
Fig. 19
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 3
and wire ropes.
14. Tighten bolts 1 with the power boost wrench and Longer bolt
torque wrench to specification.
2
(2 800 N·m/2 065 lbf·ft)
IMPORTANT: 1
Be sure to apply a film of lubricant to the bolt threads.
15. Extend the side frame on the opposite side in the Longer bolt Fig. 20
same procedure.
90 to 110° Hook the wire
16. When the loader front attachment is installed, hook rope to the tooth
the wire ropes to the teeth in the right and left
edges.
Wire rope
Raise the track slightly off the ground
Fig. 21
Torque
Model 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
186
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
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188
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
10. Checks after completing the assembly
1 After assembly, clean and wipe each part
thoroughly with a rag.
2 Inspect the excavator

before starting
CYLINDERS AND
the engine. HYDRAULIC LINES
Check for oil leaks.
PEDALS AND LEVERS
Check for freedom of
movement.
PINS AND BOLTS RESERVOIR

Check for looseness Check coolant level.
or absence.
RADIATOR
Clean fins.
OIL COOLER
Clean fins.
OPERATOR'S CAB
Clean.
HYDRAULIC TANK
Check oil level.
ENGINE Fig. 1
FINAL DRIVE Check oil level.
Check oil level.
Checks after completing of assembly
1 Electrical system
Check for worn or frayed wires and loose
connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the Operation
Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after
Fig. 2
completing assembly.
191
3 Check the instruments immediately after starting the
engine.
1 2
IMPORTANT:
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all
necessary measures. 22
1 - Coolant Temperature Gauge 21

2 - Fuel Gauge
20
3 - Display Selection Switch
4 - Set Switch 19
5 - Work Mode Switch
18
6 - Fuel Level Indicator 3
7 - Air Filter Restriction Indicator 17
8 - Alternator Indicator 4
9 - Coolant Level Indicator
10 - Quick-Idle Indicator
11 - Precision Mode Indicator 5
12 - Auto-Lubrication Indicator
13 - Engine Oil Level Indicator 16
14 - Engine Oil Pressure Indicator 6
15
15 - Preheat Indicator 7
14
16 - Overheat Indicator 8
13
17 - General Purpose Mode Indicator
9
18 - Trench Digging Mode Indicator 12
19 - Attachment Mode Indicator
20 - Liquid Crystal Display (LCD) (Hour Meter, etc.) 11 10
Fig. 3
21 - Auto-Idle Indicator
22 - Auto-Acceleration Indicator
4 Measurement of engine revolutions
Determination
Fig. 4
Standard
Item for new
machine
Low-speed idling 900 ± 100
Engine Quick idling 900 ± 100

revolutions
(rpm) Auto idling 1 250 ± 100
HP Mode 1 850 ± 100
High-speed idling
E Mode 1 820 ± 100
192
11. Checking machine performance
The figures and tolerances listed on the next page onward are
Note:
for new machines.
Measure each actuator speed after sufficiently
The measurements should be performed under the following
operating the machine.
conditions:
· Engine speed: Maximum
· Hydraulic oil temperature: 50° ± 5°C
· Site: Firm level ground
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.
1 Preparation
Fig. 1 Fig. 2
2 Measurement
1 Move both travel levers to the stroke end.

2 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
3 Determination
Front
Unit: mm (in)
Item Standard FORWARD
Deviation distance Less than 200 (7.8)
REVERSE
194
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
90° ~ 110°
90° ~ 110°
Fig. 4 Fig. 5
1 Mark any one of the track shoes on the side

where this test is to be performed.
2 Jack up the track to be tested. (Figs. 4 and 5)
2 Measurement
Front
1 Accelerate the engine to maximum speed.
2 Measure the time required to make three full FORWARD
turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
REVERSE
3 Determination
Unit: sec.
Item Standard
Fast Track link speed/

32.2±2.0
speed 3 rev.
Slow Track link speed/

3 rev. 46.1±2.0
speed
195
SWING SPEED FOR 3 FULL TURNS
1 Preparation
Fig. 6 Fig. 7
2 Measurement
1 Set the swing control lever to full stroke.

2 Measure the time required for three full turns at a
constant speed.
Front
SWING RIGHT
Three full turns
SWING LEFT
Fig. 8
3 Determination
Unit: sec.
Item Standard
Swing speed/3 rev. R 22.0±1.5
Swing speed/3 rev. L 22.0±1.5
196
AMOUNT OF COASTING DURING SWING
1 Preparation
Fig. 9 Fig. 10
1 The arm cylinder should be fully extended.

2 The bucket cylinder should be fully retracted.
MEASURE THE DIFFERENCE
3 Place an aligning mark between the swing frame
and the track frame.
4 Swing the superstructure so that the swing frame
is at 90° to the track frame.
MARK ON THE FRAME
MARK ON THE SWING BEARING
2 Measurement
1 Set the swing control lever to full stroke.

2 After swinging 180°, return the lever to the neutral
position.
3 Measure the amount of coasting.
Amount of
coasting
Swing stop
180° swing
Fig. 11
3 Determination
Unit: mm (in) Front
Item Standard
SWING RIGHT
Less than
R
Amount of 1 198 (46.7)
coasting
Less than
L
1 198 (46.7)
SWING LEFT
197
CYLINDER SPEED (Loader front)
1 Action
Fig. 12
Fig. 13
Fig. 14 Fig. 15
2 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.
3 Determination
Unit: sec.
Item Loader Front
Raise 5.2±0.4
Boom cylinder Fig. 12
Lower 4.5±0.4
Retract 2.3±0.4
Arm cylinder Fig. 13
Extend 3.1±0.4
Tilt-in 3.8±0.4
Bucket Fig. 14
Tilt-out 3.4±0.4
Open 1.2±0.3
Bucket Fig. 15
Close 1.2±0.3
198
CYLINDER SPEED (Backhoe front)
1 Action
Fig. 16
Fig. 17
2 Repeat the time measurement at least 3 times for each

item and record the average time.
Fig. 18
3 Determination
Unit: sec.
Backhoe Front
Item
ZX800 ZX850H
Raise 4.0±0.3 4.4±0.4

Boom cylinder Fig. 16
Lower 3.1±0.3 2.9±0.4
Roll-in 4.3±0.3 4.6±0.4

Arm cylinder Fig. 17
Roll-out 3.2±0.3 3.7±0.4
Roll-in 2.7±0.3 2.7±0.4

Bucket cylinder Fig. 18
Roll-out 2.7±0.3 2.8±0.4
199
AMOUNT OF HYDRAULIC CYLINDER CREEP
1 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
2 Measurement
Mark Mark
1 Stop the engine.
2 Measure the amount of creep over 5 minutes.
3 Determination
Fig. 21
Unit: mm (in)
Item Loader Front Backhoe Front

A−B = Natural lowering
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)
4 Make marks with touch-up paint if necessary.
200
NOTES
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201
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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
ø40 Gas cut
DWG. No.
8089397
205
12-2 ZX800/ZX850H Assembly Instructions Appendix (Left bracket)
ø40 Gas cut
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

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Weight: ZX800 Weight: ZX850H

Weight: ZX800 Weight: ZX850H

1 RECOGNIZE SAFETY INFORMATION

Follow recommended precautions and safe operating

2 UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous situation

WARNING indicates a potentially hazardous situation

CAUTION indicates a potentially hazardous situation

To avoid confusing machine protection with personal

Safety signs should be installed, maintained, and

Learn how to operate the machine and its controls

Keep your machine in proper working condition.

The safety messages in this chapter are intended to

4 DESIGNATE ONE LEADER AND TWO

5 CLEAN THE MACHINE REGULARLY

Do not spray water or steam inside the cab.

Wear close fitting clothing and safety equipment

You may need:

7 PREPARE FOR EMERGENCIES

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

8 PREPARE SUITABLE LIFTING TOOLS

10 SUPPORT RAISED EQUIPMENT

Falling is one of the major causes of personal injury.

Never jump on or off the machine. Never mount or

Be careful of slippery conditions on platforms, steps, Fig. 1-11

13 PREVENT BATTERY EXPLOSIONS

Never check the battery charge by placing a metal

Do not charge a frozen battery - it may explode. Warm

Disconnect the negative ground cable before working

• Avoid this hazard by relieving pressure before

• Search for leaks with a piece of cardboard, taking

• If an accident occurs, see a doctor familiar with this Fig. 1-14-1

Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4

15 CHECK EQUIPMENT SAFETY

Wear a suitable hearing protective device such as

17 FASTEN YOUR SEAT BELT

Be sure to remain seated with seat belt securely

18 BEWARE OF EXHAUST FUMES

If you must operate in a building, be sure there is

Never lubricate or service the machine while it is

Before servicing the machine.

• Park the machine on a level surface.

If a maintenance procedure must be performed with the

Inspect certain parts periodically, and repair or replace

Disconnect the battery ground cable (-) before making

Before performing any work on the machine, attach a

21 REMOVE PAINT BEFORE WELDING OR

Avoid potentially toxic fumes and dust.

Do all such work outside or in a well-ventilated area.

Remove paint before welding or heating:

1 If you sand or grind paint, avoid breathing the

2 If you use solvent or paint stripper, remove

22 PROTECT AGAINST FLYING DEBRIS

In order to avoid personal injury, keep bystanders away

Hot fluids and surfaces:

25 STORE ATTACHMENTS SAFELY

Securely store attachments and implements to prevent

Use leakproof containers when draining fluids. Do not

Allowing air conditioning refrigerants to escape into the

Inquire as to the proper way to recycle or dispose of

27 SERVICE THE AIR CONDITIONING