PDF Workshop Manual Hitachi ZX85USB-5A Hydraulic Excavator - 2 MB
The official workshop manual for the Hitachi ZX85USB-5A hydraulic excavator is your complete resource for maintenance and repair.
This manual provides detailed instructions for disassembly, inspection, and reassembly of all major components.
With technical specifications and clear diagrams, it empowers mechanics to perform complex repairs with confidence.
Ensure your excavator maintains its high performance standards with this essential guide.
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--- Page 1 ---
PART NO. WDEE-EN-00
ZX85USB-5A
HYDRAULIC EXCAVATOR
Workshop Manual
ZX85USB-5A
WORKSHOP MANUAL
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
Service Manual consists of the following separate Part No.
WDEE-EN-00
Technical Manual (Operational Principle) : Vol. No.TODEE-EN
Technical Manual (Troubleshooting) : Vol. No.TTDEE-EN
Workshop Manual : Vol. No.WDEE-EN
PRINTED IN JAPAN (K) 2014, 04 Engine Manual : Vol. No.ETADB-EN, EWADB-EN
--- Page 3 ---
SAFETY
General Precautions for Cab
Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
--- Page 4 ---
SAFETY
Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
When crossing train tracks, use wood plates in order not
to damage them.
Do not make contact with electric wires or bridges.
When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
Avoid operations that may damage the track and
undercarriage components.
During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
SA-15
--- Page 5 ---
SAFETY
Practice Safe Maintenance
To avoid accidents:
Understand service procedures before starting work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is moving.
Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving
the control levers several times. SA-028
7. Remove the key from the key switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
If a maintenance procedure must be performed with the
engine running, do not leave the machine unattended.
If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of operator's manual. SA-527
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
SA-25
--- Page 6 ---
SAFETY
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 SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Beware of Asbestos and Silicon Dust and Other
Contamination
Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
Keep bystanders out of the work site during operation.
Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-35
--- Page 7 ---
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and If a part or component cannot be removed after
Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
Orderly arrange disassembled parts. Mark and tag
Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
Measure and record the degree of wear and
Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
Precautions for Assembling
incorrect disassembling of components as well as
Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
Dirt or debris on the contact or sliding surfaces may
The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
Reason for disassembly (symptoms, failed parts, and
Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
Clogging of filters and oil, water or air leaks, if any.
Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
Loose or damaged parts.
disassembled. Apply grease before installing
Be sure that liquid-gasket-applied surfaces are clean
Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
Fit the matching marks made when disassembling
Precautions for Disassembling and assemble them.
Cap the open ends in case the hoses and pipes Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Use matching marks for easier reassembling if
necessary.
Be sure to use the specified special tools when
instructed.
W1-1-1-1
--- Page 8 ---
SECTION 1 GENERAL
Group 2 Tightening
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1 4 3 5 2
Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.
Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint. Take
care not to damage them when connecting / a- Joint Body WDAA-01-02-009
a
disconnecting.
37 °
2013/09
Description Wrench Size mm Tightening Torque 30 °
Union Nut N·m (lbf·ft)
30 ° male 17 25 (18.5) b c
19 30 (22)
22 40 (29.5) b- Male Union Joint c- Female Union Joint
27 80 (59) WDAA-01-02-010
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37 ° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
fNOTE: Tightening torque of 37 ° male coupling without
union is similar to tightening torque of 37° female.
W1-2-1-5
--- Page 9 ---
SECTION 1 GENERAL
Group 4 Bleeding Air
Bleeding Air from Fuel System
Air in the fuel system may make the engine hard to
start or make it run irregularly. After draining water and
sediment from the fuel filter, replacing the fuel filter, or
running the fuel tank dry, be sure to bleed the air from
the fuel system.
Air Bleeding Procedures
Automatic bleeding deveice is provided on this
machine.
1. Confirm that the fuel level is more than one-half of
the fuel tank capacity. If the fuel is lower, add fuel.
2. Set the key switch to the ON position and hold it for
10 to 15 seconds.
3. Start the engine and check the fuel system for fuel
leaks.
W1-4-1-3
--- Page 10 ---
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Main Pumps 1, 2
1 2
WDEA-03-08-007
5 4 3
1- Piston (9 Used) 3- Spring (6 Used) 5- Retainer
2- Cylinder Block 4- Spherical Bushing
W2-1-1-1
--- Page 11 ---
SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage
Front Idler
C D
WDCA-02-01-002
E
A
B
Unit: mm (in)
Standard Allowable Remedy
Limit
A 43 (1.69) [33.7 (1.33)] Replace
B 100 (3.94) -
C 390 (15.4) [376 (14.8)]
D 434 (17.1) -
E 22 (0.87) -
fNOTE: Values in [ ] are just for reference.
Axle and Bushing
Unit: mm (in)
Standard Allowable Remedy
Limit
Axle Outer 55.0 (2.17) [54.2 (2.13)] Replace
Diameter
Bushing Inner 55.0 (2.17) [56.0 (2.21)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness
fNOTE: Values in [ ] are just for reference.
W2-2-2-1
--- Page 12 ---
SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment
Side Cutter (3053595, 3053596)
C
D
A
B
W505-04-01-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 213 (8.39) 138 (5.43) Replace
B 250 (9.84) -
C 295 (11.6) -
D 150 (5.91) -
W2-3-1-3
--- Page 13 ---
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Removal and Installation of Cab
3
5
4
5
6
6
7
10
8
WDEE-03-08-004
1 2
9
WDAE-03-01-029
IMPORTANT Cap the open ends in case the hoses
and pipes have been disconnected. In addition, dCAUTION: Seat (3) weight: 45 kg (100 lb)
attach an identification tag onto the connectors, 5. Remove socket bolts (5) (4 used) and washers (6) (4
hoses, and pipes for assembling. Connect the used). Remove seat (3).
hoses and install the clips in case the clips which
secure the hoses have been removed. l : 6 mm
6. Remove floor mat (1).
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (2).
3. Disconnect connectors (4) (2 used).
4. Remove bolt (7), spring washer (8), and washers (9)
(2 used). Remove seat belt (10).
j : 16 mm
W3-1-1-1
--- Page 14 ---
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
1
4 5 4 6
7
2 9 4 5 8 4
WDEE-03-01-013
WDEE-03-01-012
3
31. Remove screws (1) (4 used) and screws (3) (2 used). 36. Remove bolts, washers (4) (5 used). Remove the
Remove cover (2). bracket (7) assembly.
32. Disconnect connectors (6) (2 used). j : 13 mm
33. Disconnect connectors (8) (3 used).
34. Disconnect connector (9).
35. Remove clamps (5) (3 used).
W3-1-1-11
--- Page 15 ---
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
2
4
6
3
5
4 WDEE-03-01-002 WDEE-03-01-001
2
29. Install buzzer (6) and duct (5) with screws (4) (3
used).
30. Install cover (3) with screws (2) (6 used).
W3-1-1-21
--- Page 16 ---
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Procedure to Install Cab Glass
1
Procedures to Install Right-Hand Glass (1), Rear Glass
(2), and Rear Left-Hand Sash
1. Cut off the residual adhesive from the cab (7) side
by 1 to 2 mm deep all around by using a knife or
similar.
In addition, remove the dam rubber completely.
fNOTE: Do not damage the cab (7) paint.
WBAT-06-01-099
2
2. Clean the cutting edge of adhesive at cab (7) side by
using white spirit.
WBAT-06-01-007
7
a
b
IMPORTANT: Primer should be shaken for about 1 W1SE-02-01-036
minute and mix thoroughly before opening the
cap. After opening Primer, apply Primer as quickly a- Knife b- Cut off adhesive by 1 to 2
as possible and close the cap immediately after mm deep.
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
7
the cap off).
3. Apply Primer for paint (SUNSTAR #435-95) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.
W1SE-02-01-038
c- Apply Primer by using a d- Cutting edge of adhesive at
brush. cab (7) side
W3-1-2-9
--- Page 17 ---
SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight
3
4
5
6
1
WDEB-03-02-003 WDEB-03-05-007
2
Installation
dCAUTION:
(3180 lb)
Counterweight (4) weight: 1440 kg 4. Install cover (1) with bolts, washers (2) (4 used).
j : 17 mm
1. Install the Freno-Linkbolt (A-24, M20, Pitch 3.0 mm)
to the cap (3) mounting holes (2 places). Attach m : 50 N·m (5 kgf·m, 37 lbf·ft)
the wire ropes onto the Freno-Linkbolts. Hoist
counterweight (4).
2. Install counterweight (4) with washers (5) (3 used)
and bolts (6) (3 used).
j : 41 mm
m : 1300 N·m (130 kgf·m, 960 lbf·ft)
3. Remove the Freno-Linkbolts from the cap (3)
mounting holes (2 places). Install caps (3) (2 used).
W3-2-1-5
--- Page 18 ---
SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame
5 1
4
2
3 WDEE-04-03-001
17. Install the engine (Refer to W3-4-1.) 23. Install cover (2) with bolts, washers (3) (2 used).
18. Install the cab. (Refer to W3-1-1.) j : 17 mm
19. Install the front attachment. (Refer to W5-1-1.)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
20. Install the boom cylinder. (Refer to W5-2-1.)
24. Install cover (5) with bolt, washers (1) (2 used) and
21. Bleed air from the hydraulic system. (Refer to W1-4- bolts, washers (4) (2 used).
1.)
j : 17 mm
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks. m : 50 N·m (5 kgf·m, 37 lbf·ft)
22. Install the counterweight. (Refer to W3-2-1.)
W3-3-1-7
--- Page 19 ---
SECTION 3 UPPERSTRUCTURE
Group 4 Engine
1
6 2
3
5
4
WDEB-03-04-005
WDEB-03-04-006
33. Remove clamp (3). Disconnect the engine side of 37. Disconnect connectors (16) (3 used). Remove caps
hose (5). (7) (3 used). Remove nut (8) and washer (9). Remove
screw (10). Remove clamps (15) (4 used). Remove
34. Remove clamp (1). Disconnect the air cleaner side of
harness (18).
hose (6). Remove the resonator (2) assembly.
35. Remove counterweight (4). (Refer to W3-2-1.) j : 13 mm
36. Remove the pump device. (Refer to W3-5-1.) 38. Remove nut (11) and washer (12). Disconnect
terminal (17).
j : 13 mm
39. Remove bolts, washers (13) (2 used). Remove
bracket (14).
j : 17 mm
W3-4-1-9
--- Page 20 ---
SECTION 3 UPPERSTRUCTURE
Group 4 Engine
1
4, 5
3
2 1
WDEB-03-04-016
20. Install harness (3) with clamps (2) (2 used).
21. Connect connectors (1) (6 used).
22. Install nut (5) and cap (4).
j : 10 mm
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
W3-4-1-19
--- Page 21 ---
SECTION 3 UPPERSTRUCTURE
Group 4 Engine
1
MDEC-07-008
61. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
Pump Air Bleed Plug
j : 27 mm
m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
62. Close door (1).
W3-4-1-29
--- Page 22 ---
SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device
1
2
5
3
4
7, 8 a
3
6
9
WDEB-03-05-010 WDEB-03-05-009
7. Install muffler (4) with U-bolts (5) (2 used) and nuts 10. Install the cover (2) assembly with bolts, washers (1)
(6) (4 used). (2 used) and bolts, washers (3) (4 used).
j : 17 mm j : 17 mm