Description

Hitachi Sumitomo ZAXIS 800, ZAXIS 850H Technical Manual – Factory Assembly Specs

You ever crack open a manual and realize the guy who wrote it never turned a wrench? I have. That is not what you get here. This is the actual factory Hitachi Sumitomo ZAXIS 800, ZAXIS 850H Technical Manual – the same booklet that Hitachi’s own assembly techs use. 210 pages of procedures that start with safety precautions and end with lifting diagrams. If you are assembling a ZX800 or ZX850H from knocked-down components, you need this on the bench next to your torque wrench.

7 Systems Covered in the Assembly Sequence

This manual is not a repair guide – it is an assembly procedure document. That means it covers every step from uncrating the superstructure to final trial operation. The table of contents breaks it into seven main blocks: Precautions, Work Plan & Preparations, Parts Check, Preparations (backhoe and loader front), Superstructure Assembly, Backhoe Front Mounting, and Loader Front Mounting. Side-by-side assembly charts for backhoe and loader configurations give you the weights and dimensions before you pick up a sling. Weight for the ZX800 backhoe front: 73,900 kg (162,900 lb). You need to know that before you rig.

Torque Specs and Bolt Tightening Procedures

Section 1-2 is titled “How to use a power wrench” – not because Hitachi thinks you are stupid, but because they know a ugga-dugga with a 1-inch gun will snap bolts if you skip steps. Tightening torque values for all critical fasteners are listed throughout the procedure chapters. For the swing bearing grease and bolt pattern, you go to Chapter 6-4. For the side frame connection to the track frame, Chapter 6-2 tells you the sequence and torque. Do not guess. The manual states the tightening torque values of bolts, etc. – exactly what you need to avoid pulling threads in a 75-ton machine.

Hydraulic System Bleeding: Why You Need the Factory Procedure

Chapter 6-6 covers releasing air from the main pumps. Chapter 7-3 and 8-3 handle bleeding the cylinders for backhoe and loader fronts respectively. Aftermarket documentation will tell you to “crack a line and crank until fluid comes out” – which is how you blow a seal. The OEM procedure specifies which port to open, in what order, and how long to run the engine at idle. Miss that step and you are replacing a $4,000 pump. The manual also includes a final trial operation check (Sections 7-5 and 8-5) where you verify pressures before putting the bucket in the dirt.

Safety First: Precautions for Servicemen and Lift Points

Section 1-1 is safety precautions for servicemen. It covers what to do when working under a raised superstructure, how to use wire ropes with the correct sling angles, and the lifting jig dimensions in the Appendix (Chapter 12-3). The manual even lists the weight of each major component so you can select the correct crane capacity. For a ZX850H backhoe front, that is 75,900 kg (167,000 lb). If your rigging is undersized, you are not just losing time – you are losing a machine and maybe a coworker. The manual lays this out before you lay a finger on a bolt.

Does This Manual Cover the Loader Front Conversion?

Yes. The manual splits the mounting procedure into two parallel tracks. Chapter 7 is for the backhoe front configuration (3.6 m H-arm, 3.4 m³ bucket). Chapter 8 is for the loader front configuration with standard bottom dump or tilt dump buckets. Both include lubrication charts, track tension adjustment (Sections 7-4 and 8-4), and final checklists. If you are swapping between loader and backhoe on the same superstructure, you use the same superstructure assembly steps from Chapter 6 and then follow the specific front-end chapter. Page 73 covers the track link tension spec – 7 mm slack on the upper run between rollers. Do not over-tighten or you will cook the final drive bearings.

Source Validity: OEM Print vs. Aftermarket Copies

I have seen aftermarket “repackaged” manuals that leave out the assembly chart and skip the safety precautions. This file is a direct scan of the Hitachi Construction Machinery Co., Ltd. binder – part number KO-282-00. The foreword is written by Hitachi’s assembly engineering team. If you buy a third-party PDF that cuts corners on the lifting diagrams, you are on your own. This one has the full Appendix (Chapter 12-1 through 12-3) with the right and left bracket lifting jig drawings. That is factory data, not an intern’s guess. For related models, check the Hitachi Sumitomo ZAXIS 800 850H 2004 Operators Manual – Factory Specs and the Hitachi Sumitomo 330LC, 350H, 350LCH, 370MTH, ZX330 Technical Manual. For a different size machine, the Hitachi Sumitomo SH200-3 SH220-3 Technical Manual 166 Pages covers that compact excavator line.

FAQ

What year model does this cover?

This technical manual covers the ZAXIS 800 and ZAXIS 850H series. The publication year is not printed on the cover, but the assembly chart weights and bucket options match the early 2000s production run. If you need a specific model year VIN breakdown, contact Hitachi with the serial number.

Can I use this for repair, not just assembly?

No. This is an assembly procedure manual. It does not include diagnostics, electrical schematics, or disassembly steps. For repair, get the separate service manual.

I have been turning wrenches for 28 years. The first thing I do when a machine shows up in pieces is grab the factory assembly manual and check the torque spec for the swing bearing bolts. This manual gives you that – along with blood pressures for the hydraulics, lifting jig dimensions, and a final trial operation checklist. You want to put a 75-ton excavator together without guessing? Access the Factory Manual from AutoRepairManuals right now. Keep it on your tablet in the cab. The alternative is a phone call to the dealer asking “how tight is tight?” – and I guarantee they charge by the minute.