Hitachi ZX500LC Excavator Pdf Operator Manual (EM16R-EN1-1)

Hitachi ZX500LC Excavator Pdf Operator Manual (EM16R-EN1-1)

This manual provides essential guidance for operators and maintenance personnel to ensure safe, efficient, and reliable machine performance. This comprehensive manual includes detailed operating instructions, safety guidelines, maintenance schedules for Hitachi ZX500LC Excavator model.

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

Language: English
Format: PDF

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