Description

Hitachi ZX500LC Excavator Operator’s Manual (EM16R-EN1-1)

ZX500LC Excavator Index:

MACHINE NUMBERS
SAFETY
Recognize Safety Information ………………………. S-1
Understand Signal Words…………………………….. S-1
Follow Safety Instructions…………………………….. S-2
Prepare for Emergencies……………………………… S-2
Wear Protective Clothing……………………………… S-3
Protect Against Noise ………………………………….. S-3
Inspect Machine………………………………………….. S-3
General Precautions for Cab ………………………… S-4
Use Handholds and Steps……………………………. S-5
Adjust the Operator’s Seat……………………………. S-5
Fasten Your Seat Belt………………………………….. S-6
Move and Operate Machine Safely ……………….. S-6
Operate Only from Operator’s Seat……………….. S-7
Jump Starting……………………………………………… S-7
Keep Riders off Machine ……………………………… S-7
Investigate Job Site Beforehand……………………. S-8
Protect Against Falling Stones and Debris……… S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines…………………………….. S-9
Confirm Direction of Machine to be Driven……… S-9
Drive Machine Safely…………………………………. S-10
Avoid Injury from Rollaway Accidents ………….. S-11
Avoid Injury from Back-Over
and Swing Accidents ……………………………. S-12
Keep Person Clear from Working Area ………… S-13
Never Position Bucket Over Anyone ……………. S-13
Avoid Undercutting ……………………………………. S-13
Avoid Tipping ……………………………………………. S-14
Never Undercut A High Bank ……………………… S-14
Dig with Caution………………………………………… S-15
Operate With Caution ………………………………… S-15
Avoid Power Lines …………………………………….. S-15
Object Handling ………………………………………… S-16
Protect Against Flying Debris ……………………… S-16
Park Machine Safely………………………………….. S-17
Handle Fluids Safely-Avoid Fires ………………… S-17
Practice Safe Maintenance…………………………. S-18
Warn Others of Service Work……………………… S-19
Support Machine Properly ………………………….. S-19
Stay Clear of Moving Parts…………………………. S-19
Prevent Parts from Flying …………………………… S-20
Store Attachments Safely …………………………… S-20
Prevent Burns …………………………………………… S-21
Replace Rubber Hoses Periodically…………….. S-21
Avoid High-Pressure Fluids ………………………… S-22
Prevent Fires ……………………………………………. S-23
Evacuating in Case of Fire………………………….. S-24
Beware of Exhaust Fumes………………………….. S-24
Precautions for Welding and Grinding………….. S-25
Avoid Heating Near Pressurized Fluid Lines…. S-26
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………… S-26
Remove Paint Before Welding or Heating…….. S-26
Prevent Battery Explosions ………………………….S-27
Service Air Conditioning System Safely…………S-27
Handle Chemical Products Safely ………………..S-28
Dispose of Waste Properly…………………………..S-28
SAFETY SIGNS ……………………………. S-29
COMPONENTS NAME ……………………. 1-1
GETTING ON/OFF THE MACHINE …… 1-2
OPERATOR’S STATION
Cab Features………………………………………………. 1-3
Monitor Panel ……………………………………………… 1-4
Coolant Temperature Gauge …………………. 1-5
Fuel Gauge ………………………………………….. 1-5
Auto-Idle Indicator ………………………………….. 1-5
Auto-Acceleration Indicator……………………… 1-5
Fuel Level Indicator………………………………… 1-6
Air Filter Restriction Indicator…………………… 1-6
Overheat Indicator………………………………….. 1-6
Engine Oil Pressure Indicator ………………….. 1-6
Alternator Indicator…………………………………. 1-6
Engine Oil Level Indicator ……………………….. 1-7
Coolant Level Indicator …………………………… 1-7
Preheat Indicator……………………………………. 1-7
Precision Mode Indicator ………………………… 1-7
Auto-Lubrication Indicator ……………………….. 1-7
Liquid Crystal Display (LCD)……………………. 1-8
Display Selection Switch…………………………. 1-8
Hour Meter ……………………………………………. 1-8
Trip Meter 1 and Trip Meter 2 ………………….. 1-9
User’s Mode………………………………………….. 1-9
Set Switch …………………………………………… 1-10
Work Mode Switch ……………………………….. 1-11
Switch Panel ……………………………………………. 1-12
Engine Control Dial ………………………………. 1-12
Auto-Idle/Acceleration Selector………………. 1-13
Power Mode Switch ……………………………… 1-14
Travel Mode Switch………………………………. 1-14
Work Light Switch ………………………………… 1-15
Wiper/Washer Switch ZAXIS500LC ……….. 1-16
Wiper/Washer Switch ZAXIS500LCH……… 1-17
Switch Panel (Optional)………………………………. 1-18
Key Switch………………………………………………… 1-20
Power Boost Switch …………………………………… 1-20
Horn Switch………………………………………………. 1-20
Lighter …………………………………………………….. 1-21
Cab Light ………………………………………………….. 1-22
Installing Fire Extinguisher ………………………….. 1-22
Pilot Control Shut-Off Lever ………………………… 1-23
Engine Stop Knob ……………………………………… 1-23
Fuse Box ………………………………………………….. 1-24
Air Conditioner Operation……………………………. 1-25
Auto Air Conditioner …………………………………… 1-26
Cab Heater Operation ………………………………… 1-32
Cooling Operation ……………………………………… 1-32
CONTENTS
Defroster Operation …………………………………….1-33
Tips for Optimal Air Conditioner Usage………….1-34
AM/FM Radio Operation ………………………………1-36
Digital Clock Setting Procedure…………………….1-37
Cab Door Release Lever ……………………………..1-38
Opening Upper Front Window
(ZAXIS500LC) ………………………………………1-38
Closing Upper Front Window
(ZAXIS500LC) ………………………………………1-39
Removing and Storing Lower
Front Window (ZAXIS500LC)………………….1-40
Opening Side Windows (ZAXIS500LC)………….1-41
Opening/Closing Overhead Window
(ZAXIS500LC) ………………………………………1-42
Emergency Exit (ZAXIS500LC) …………………….1-43
Headguard-Integrated Cab…………………………..1-44
Emergency Exit (Headguard-Integrated Cab) …1-45
Adjusting the Seat……………………………………….1-46
Adjusting Console Height …………………………….1-48
Seat Belt ……………………………………………………1-49
BREAK-IN
Observe Engine Operation Closely …………………2-1
Every Eight Hours or Daily……………………………..2-1
After The First 50 Hours ………………………………..2-1
After The First 100 Hours ………………………………2-1
OPERATING THE ENGINE
Inspect Machine Daily Before Starting …………….3-1
Before Starting Engine…………………………………..3-2
Level Check …………………………………………………3-3
Starting the Engine in Ordinary Temperature……3-4
Starting in Cold Weather………………………………..3-5
Check Instruments After Starting…………………….3-6
Using Booster Batteries …………………………………3-7
Stopping the Engine ……………………………………..3-9
DRIVING THE MACHINE
Drive the Machine Carefully …………………………..4-1
Steering the Machine Using Pedals ………………..4-2
Steering the Machine Using Levers…………………4-3
Travel Mode Switch ………………………………………4-4
Travel Alarm (Optional)………………………………….4-4
Traveling ……………………………………………………..4-5
Operating on Soft Ground………………………………4-6
Raise One Track Using Boom and Arm …………..4-6
Towing Machine a Short Distance…………………..4-7
Operating in Water or Mud …………………………….4-8
Precautions for Traveling on Slopes………………..4-9
Parking the Machine on Slopes…………………….4-10
Parking the Machine ……………………………………4-10
OPERATING THE MACHINE
Control Lever (ISO Pattern) ………………………….5-1
Control Lever (HITACHI Pattern) …………………..5-2
Pilot Control Shut-Off Lever……………………………5-3
Engine Speed Control……………………………………5-6
Auto-Idle …………………………………………………….. 5-7
Auto Acceleration ………………………………………… 5-8
Work Mode……………………………………………….. 5-10
Power Boost ……………………………………………… 5-10
Power Mode ……………………………………………… 5-11
Precautions for Operations …………………………. 5-12
Operate the Machine Safely………………………… 5-13
Operating Backhoe ……………………………………. 5-14
Grading Operation……………………………………… 5-14
Face Shovel Operation ………………………………. 5-15
Avoid Abusive Operation…………………………….. 5-15
Operating Tips…………………………………………… 5-16
Select Correct Track Shoes ………………………… 5-16
Precaution for Arm Roll-In/ Bucket Roll-In
Combined Operation…………………………….. 5-17
Object Handling — If Equipped……………………. 5-18
Electronic Control System Bypass Procedure .. 5-19
Overnight Storage Instructions…………………….. 5-20
TRANSPORTING
Transporting by Road…………………………………… 6-1
Transporting the Machine by Trailer ………………. 6-1
Loading/Unloading on a Trailer……………………… 6-1
Backhoe (ZAXIS500LC)……………………………….. 6-5
Backhoe (ZAXIS500LCH) …………………………….. 6-8
Retracting or Extending the Side Frame……….. 6-11
Retracting the Side Frame ………………………….. 6-12
Extending the Side Frame…………………………… 6-13
Counterweight Removal — If Equipped………… 6-16
Counterweight Installation — If Equipped……… 6-22
MAINTENANCE
Correct Maintenance
and Inspection Procedures ……………………… 7-1
Check the Hour Meter Regularly……………………. 7-2
Use Correct Fuels and Lubricants …………………. 7-2
Prepare Machine for Maintenance…………………. 7-3
Hood and Access Covers……………………………… 7-4
Periodic Replacement of Parts………………………. 7-5
Hydraulic System ………………………………………… 7-6
Main Circuit ………………………………………………… 7-7
ZX500LC/500LCH Electrical Circuit Diagram ….. 7-9
Maintenance Guide ……………………………………. 7-11
A. Greasing ……………………………………………. 7-14
Auto Lubrication — If Equipped ……………… 7-15
Front Joint Pins ……………………………………. 7-16
Swing Bearing ……………………………………… 7-18
Electric Grease Gum — If Equipped……….. 7-19
Swing Internal Gear ……………………………… 7-23
B. Engine Oil……………………………………………. 7-24
Engine Oil Level …………………………………… 7-25
Change Engine Oil ……………………………….. 7-25
Replace Engine Oil Filters …………………….. 7-25
C. Oil …………………………………………………… 7-28
Swing Reduction Gear ………………………….. 7-29
Travel Reduction Gear………………………….. 7-31

D. Hydraulic System…………………………………..7-33
Inspection and Maintenance
of Hydraulic Equipment …………………….7-34
Check Hydraulic Oil Level ………………………7-36
Drain Hydraulic Oil Tank Sump……………….7-38
Change Hydraulic Oil……………………………..7-39
Suction Filter Cleaning …………………………..7-39
Replace Hydraulic Oil Tank Filter…………….7-42
Replace Pump Drain Filter ……………………..7-43
Replace Pilot Oil Filter ……………………………7-44
Check Hoses and Lines………………………….7-45
Service Recommendations for Hydraulic
Fittings ……………………………………………7-48
E. Fuel System………………………………………….7-50
Refueling………………………………………………7-50
Drain Fuel Tank Sump……………………………7-52
Check Water Separator ………………………….7-52
Bleed Air from Fuel System…………………….7-53
Replace Fuel Filter ………………………………..7-54
Clean Feed Pump Strainer ……………………..7-54
Check Fuel Hoses …………………………………7-55
F. Air Cleaner……………………………………………7-56
Clean Air Cleaner Outer Element…………….7-56
Replace Air Cleaner Outer
and Inner Elements ………………………….7-56
G. Cooling System……………………………………..7-58
Check Coolant Level ……………………………..7-60
Check and Adjust Fan Belt Tension …………7-60
Change Coolant…………………………………….7-61
Clean Radiator Interior …………………………..7-61
Clean Radiator Core………………………………7-62
Clean Radiator Interior …………………………..7-62
Clean Oil Cooler Front Screen ………………..7-62
H. Air Conditioner………………………………………7-63
Clean and Replace Air Conditioner Filter ….7-64
Check Refrigerant (Gas) Quantity ……………7-66
Check Compressor Belt Tension……………..7-66
Clean Condenser Core…………………………..7-67
Check Looseness at Each of
Fastened Areas ……………………………….7-67
Check In-Season and Off-Season……………7-68
I. Electrical System …………………………………7-69
Batteries……………………………………………….7-69
Replace Batteries ………………………………….7-73
Replacing Fuses……………………………………7-73
Connecting Batteries ……………………………..7-74
J Miscellaneous ……………………………………..7-75
Check Bucket Teeth ………………………………7-76
Change Bucket ……………………………………7-81
Convert Bucket Connection Into
Face Shovel…………………………………….7-82
Adjust the Bucket Linkage (Backhoe) ………7-83
Remove the Travel Levers ……………………..7-84
Check and Replace Seat Belt ………………..7-85
Check Windshield Washer Fluid Level……..7-85
Check Track Sag …………………………………..7-86
Adjust Track Sag………………………………….. 7-86
Loosen the Track …………………………………. 7-87
Tighten the Track …………………………………. 7-87
Replace the Track………………………………… 7-87
Clean Cab Floor …………………………………… 7-88
Check Tightening Torque of Bolts
and Nuts………………………………………… 7-89
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions ……………………….. 9-1
STORAGE
Storing the Machine …………………………………… 10-1
Removing the Machine from Storage …………… 10-2
Installing Vandal-Proof Covers…………………….. 10-3
Help Prevent Crime……………………………………. 10-4
Record Identification Numbers…………………….. 10-4
Keep Proof of Ownership ……………………………. 10-4
Park Indoors out of sight …………………………….. 10-4
When Parking Outdoors……………………………… 10-5
Reduce Vandalism …………………………………….. 10-5
Report Thefts Immediately ………………………….. 10-5
TROUBLESHOOTING
Engine …………………………………………………….. 11-1
Electrical System……………………………………….. 11-5
Mode Selection………………………………………….. 11-8
Control Levers …………………………………………… 11-9
Hydraulic System ………………………………………. 11-9
SPECIFICATIONS
ZAXIS500LC (Backhoe)
Specifications ……………………………………………. 12-1
Working Ranges ………………………………………. 12-2
Shoe Types and Applications………………………. 12-3
Bucket Types and Applications ………………….. 12-4
ZAXIS500LCH (Backhoe)
Specifications …………………………………….. 12-5
Working Ranges………………………………………… 12-6
Shoe Types and Applications………………………. 12-7
Bucket Types and Applications……………………. 12-8
Lifting Capacities……………………………………….. 12-9
Sound Level Results (89/514/EEC) ……………. 12-15
OPTIONAL ATTACHMENTS AND
DEVICES
Hydraulic Breaker………………………………………. 13-1
Breaker Operation……………………………………… 13-2
Precautions for Breaker Operation ………………. 13-4
Breaker Maintenance …………………………………. 13-8
Replace Breaker Circuit Return Oil Filter………. 13-9
Hydraulic Crusher ……………………………………. 13-10
Stop Valve Operation ……………………………….. 13-11
Three-Way-Valve Operation ……………………… 13-12
CONTENTS
Flow Combining Valve Operation………………..13-12
Precautions for Crusher Operation………………13-13
INDEX……………………………………………………..14-1

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