All-Inclusive Factory Service Technical manual for Hitachi Crawler Excavators Models Zaxis 800 and Zaxis 850H.

This manuals will assist you in diagnosing, repairing, performing perfomance checks, troubleshooting, maintaining, operating, and assembling for your crawler excavator.
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Covered Models:
   Zaxis 800
   Zaxis 850H

The manual comprises 8 documents, including two Workshop Manuals, the Perfomance Check and Troubleshooting Manual, Maintenance Manual, Operational Principle Manual, Operators Manual, Wiring Diagram, and Assembly Manual

1. Workshop Manual (W17VE-00_updated+information_1pages)
Format: PDF, 1 page
Language: English

2. Workshop Manual (W17VE-00)
Format: PDF, 624 pages
Language: English
Table of Contents:
   General Information
      General Repair Instruction
      Illustration Arrows
      Abbreviations
      Nut and Bolt Angular Tightening Method
      Standard Bolt Torque Specifications
      Recommended Thread Locking Agents
      Main Data and Specifications
      Engine External Drawing
      Service Standard
      Torque Specifications
      Special Tools
      Troubleshooting
      Lubricant Application
      Sealant Application
   SERVICE INFORMATION
      Identification
      Lubrication System
      Fuel System
      Cooling System
      Valve Clearance Adjustment
      Compression Pressure Measurement
      Recommended Lubricants
      Engine Oil Viscosity Chart
   ENGINE MECHANICAL
      Service Precautions
      General Description
      Engine Cleanliness and Care
      General Information on Engine Service
      FanCenter
      Turbocharger
      ExhaustManifold
      InletManifold
      Water Pump
      Alternator
      Oil Cooler
      Injection Pump
      Coupling Assembly
      Cylinder Head
      Rocker Arm and Shaft Assembly
      Camshaft
      Timing Gears
      Flywheel Housing
      Oil Pan
      Piston
      Crankshaft
      Crank Pulley
      Flywheel
      Cylinder Block
   ENGINE COOLING
      Service Precaution
      General Description
      Water Pump
      Thermostat
   ENGINE FUEL
      Service Precaution
      General Description
      Fuel Filter
      Injection Nozzle Holder
      Injection Pump
   STARTING AND CHARGING
      Service Precaution
      Alternator
      Starter Motor
   ENGINE LUBRICATION
      Service Precaution
      General Description
      Oil Pump
      Oil Cooler
      Main Oil Filter
      Partial Oil Filter
   ENGINE INDUCTION
      Service Precaution
      Turbocharger

3. Perfomance Check and Troubleshooting Manual (TTLA0503)
Format: PDF, 319 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Excavator Test
      Component Test
      Adjustment
   TROUBLESHOOTING
      General
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Electrical System Inspection
      ICX

4. Maintenance Manual (TTLA0505)
Format: PDF, 177 pages
Language: English
Table of Contents:
   ASSEMBLING
      PRECAUTIONS FOR ASSEMBLING
      PRECAUTIONS FOR SLINGING WORK
      PRECAUTIONS FOR OPERATING MACHINE
      INSTALLING COUNTERWEIGHT
      INSTALLING BOOM CYLINDER (BACKHOE)
      INSTALLING BOOM (BACKHOE)
      CONNECTING HOSES BETWEEN BOOM AND MACHINE (BACKHOE)
      INSTALLING BOOM CYLINDER ROD (BACKHOE)
      INSTALLING ARM (BACKHOE)
      CONNECTING ARM CYLINDER ROD (BACKHOE)
      CONNECTING BUCKET CYLINDER HOSES (BACKHOE)
      INSTALLING BUCKET (BACKHOE)
      CONNECTING PIPINGS (LOADING SHOVEL)
      INSTALLING LOADING SHOVEL FRONT
      REMOVING STOPPER AND WIRE (LOADING SHOVEL)
      CONNECTING HOSES BETWEEN BOOM AND MACHINE (LOADING SHOVEL)
      INSTALLING BOOM CYLINDER (LOADING SHOVEL)
      BLEEDING AIR FROM ARM AND BUCKET CYLINDERS (LOADING SHOVEL)
      INSTALLING LOADING SHOVEL BUCKET
      CONNECTING DUMP CYLINDER HOSE (LOADING SHOVEL)
      EXTENDING THE SIDE FRAME
   TRANSPORTING
      TRANSPORTING BY ROAD
      TRANSPORTING THE MACHINE BY TRAILER
      LOADING/UNLOADING ON A TRAILER
      TYPES OF PACKINGS FOR TRANSPORTATION
      PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-1 (BACKHOE)
      PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-2 (BACKHOE)
      PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-1 (LOADING SHOVEL)
      PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION-2 (LOADING SHOVEL)
      RETRACTING OR EXTENDING THE SIDE FRAME
      RETRACTING THE SIDE FRAME
      EXTENDING THE SIDE FRAME
   MAINTENANCE
      CORRECT MAINTENANCE AND INSPECTION PROCEDURES
      CHECK THE HOUR METER REGULARLY
      USE CORRECT FUELS AND LUBRICANTS
      PREPARE MACHINE FOR MAINTENANCE
      HOOD AND ACCESS COVERS
      PERIODIC REPLACEMENT OF PARTS
      USE ELECTRICAL OUTLET (OPTIONAL)
      HYDRAULIC SYSTEM
      MAIN CIRCUIT (BACKHOE)
      MAIN CIRCUIT (LOADER)
      ZX800 ELECTRICAL CIRCUIT DIAGRAM
      MAINTENANCE GUIDE
   J. MISCELLANEOUS
      Check Bucket Teeth
      Change Bucket
      Adjust Bucket Linkage
      Remove the Travel Levers
      Check and Replace Seat Belt Check
      Check Windshield Washer Fluid Level
      Check Track Sag
      Adjust Track Sag Precautions for Adjusting Track Sag
      Clean Cab Floor
      Check Tightening Torque of Bolts and Nuts
   MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
      MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
   STORAGE
      STORING THE MACHINE
      REMOVING THE MACHINE FROM STORAGE
      INSTALLING VANDAL-PROOF COVERS
      HELP PREVENT CRIME
      RECORD IDENTIFICATION NUMBERS
      KEEP PROOF OF OWNERSHIP
      PARK INDOORS OUT OF SIGHT
      WHEN PARKING OUTDOORS
      REDUCE VANDALISM
      REPORT THEFTS IMMEDIATELY
   TROUBLESHOOTING
      ENGINE
      ELECTRICAL SYSTEM
      MODE SELECTION
      CONTROL LEVERS
      HYDRAULIC SYSTEM
      PUMP CONTROL SYSTEM

5. Operational Principle Manual (TTLA0502)
Format: PDF, 213 pages
Language: English
Table of Contents:
   GENERAL
      Specification
      Component Layout
      Component Specifications
   SYSTEM
      Control System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Travel Device
      Signal Control Valve
      Others (Upperstructure)
      Others (Undercarriage)

6. Operators Manual (TTLA0504)
Format: PDF, 115 pages
Language: English
Table of Contents:
   OPERATOR'S STATION
      CAB FEATURES
      MONITOR PANEL
      SWITCH PANEL
      SWITCH PANEL
      KEY SWITCH
      QUICK-IDLE SWITCH
      HORN SWITCH
      CIGER LIGHTER
      CAB LIGHT
      INSTALLING FIRE EXTINGUISHER
      PILOT CONTROL SHUT-OFF LEVER
      ENGINE STOP KNOB
      FUSE BOX
      AIR CONDITIONER OPERATION
      AUTO AIR CONDITIONER
      CAB HEATER OPERATION
      COOLING OPERATION
      DEFROSTER OPERATION
      TIPS FOR OPTIMAL AIR CONDITIONER USAGE
      AM/FM RADIO OPERATION
      DIGITAL CLOCK SETTING PROCEDURE
      CAB DOOR RELEASE LEVER
      OPENING UPPER FRONT WINDOW (ZAXIS800)
      CLOSING UPPER FRONT WINDOW (ZAXIS800)
      REMOVING AND STORING LOWER FRONT WINDOW (ZAXIS800)
      OPENING SIDE WINDOWS (ZAXIS800)
      OPENING/CLOSING OVERHEAD WINDOW (ZAXIS800)
      EMERGENCY EXIT (ZAXIS800)
      HEADGUARD-INTEGRATED CAB (ZAXIS850H)
      EMERGENCY EXIT (HEAD- GUARD-INTEGRATED CAB) (ZAXIS850H)
      ADJUSTING THE SEAT
      ADJUSTING CONSOLE HEIGHT
      SEAT BELT
   BREAK-IN
      OBSERVE ENGINE OPERATION CLOSELY
      EVERY EIGHT HOURS OR DAILY
      AFTER THE FIRST 50 HOURS
      AFTER THE FIRST 100 HOURS
   OPERATING THE ENGINE
      INSPECT MACHINE DAILY BEFORE STARTING
      BEFORE STARTING ENGINE
      LEVEL CHECK
      STARTING THE ENGINE
      STARTING IN COLD WEATHER
      CHECK INSTRUMENTS AFTER STARTING
      USING BOOSTER BATTERIES
      STOPPING THE ENGINE
   DRIVING THE MACHINE
      DRIVE THE MACHINE CAREFULLY
      STEERING THE MACHINE USING PEDALS
      STEERING THE MACHINE USING LEVERS
      TRAVEL MODE SWITCH
      TRAVEL ALARM (Optional)
      TRAVELING
      OPERATING ON SOFT GROUND
      RAISE ONE TRACK USING BOOM AND ARM
      TOWING MACHINE A SHORT DISTANCE
      OPERATING IN WATER OR MUD
      PRECAUTIONS FOR TRAVELING ON SLOPES
      PARKING THE MACHINE ON SLOPES
      PARKING THE MACHINE
   OPERATING THE MACHINE
      CONTROL LEVER (ISO PATTERN)
      CONTROL LEVER (HITACHI PATTERN)
      CONTROL LEVER(ISO PATTERN LOADING SHOVEL)
      CONTROL LEVER(HITACHI PATTERN LOADING SHOVEL)
      BUCKET OPEN-CLOSE PEDALS (LOADING SHOVEL)
      PILOT CONTROL SHUT-OFF LEVER
      ENGINE SPEED CONTROL
      AUTO-IDLE
      AUTO-ACCELERATION
      WORK MODE
      QUICK-IDLE
      POWER MODE
      PRECAUTIONS FOR OPERATIONS
      OPERATE THE MACHINE SAFELY
      OPERATING BACKHOE
      GRADING OPERATION
      FACE SHOVEL OPERATION
      AVOID ABUSIVE OPERATION
      OPERATING TIPS
      SELECT CORRECT TRACK SHOES
      PRECAUTION FOR ARM ROLL-IN/ BUCKET ROLL-IN COMBINED OPERATION
      LOADING SHOVEL OPERATION
      STRAIGHT RETRACTION OPERATION
      PROHIBITED OPERATIONS (LOADING SHOVEL)
      PRECAUTIONS FOR OPERATION (LOADING SHOVEL)
      OBJECT HANDLING --- IF EQUIPPED
      ELECTRONIC CONTROL SYSTEM BYPASS PROCEDURE
      OVERNIGHT STORAGE INSTRUCTIONS
   OPTIONAL ATTACHMENTS AND DEVICES
      HYDRAULIC BREAKER
      BREAKER OPERATION
      PRECAUTIONS FOR BREAKER OPERATION
      BREAKER MAINTENANCE
      REPLACE BREAKER CIRCUIT RETURN OIL FILTER
      HYDRAULIC CRUSHER
      PRECAUTIONS FOR CRUSHER OPERATION

7. Wiring Diagram (ZX800_elec_hyd)
Format: PDF, 9 pages
Language: English

8. Assembly Manual (KO-282-00)
Format: PDF, 210 pages
Language: English
Table of Contents:
   COVER
   Foreword
   ZX800/ ZX850H Assembly Chart BACKHOE FRONT
   ZX800/ ZX850H Assembly Chart BACKHOE FRONT
   ZX800/ ZX850H Assembly Chart LOADER FRONT
   ZX800/ ZX850H Assembly Chart LOADER FRONT
      1. Precautions
      2. Work Plan and Preparations
      3. Parts check
      4. Preparations
      5. Machines, apparatuses, tools, and materials necessary for assembly
      ASSEMBLY OF SUPERSTRUCTURE
      MOUNTING PROCEDURE FOR FRONT-END ATTACHMENTS BACKHOE FRONT
      MOUNTING PROCEDURE FOR FRONT-END ATTACHMENTS LOADER FRONT
      9. Extending and retracting the side frames
      CHECKS & PERFORMANCE STANDARDS
      12. Appendix (Lifting Diagrams)
   BACK COVER