Professional Documents
Culture Documents
INTRODUCTION
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
2
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0001
SA-001
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
008-E01A-0439
009-E01A-0378
SA-4
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
machine.
011-E01A-0426
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
JUMP STARTING
SA-6
SAFETY
KEEP RIDERS OFF MACHINE
SA-379
014-E01B-0379
018-E01A-0481
SA-481
SA-7
SAFETY
DRIVE MACHINE SAFELY
SA-388
SA-441
S019-E02B-0590
SA-589
SA-8
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch off. SA-391
020-E02A-0493 SA-392
SA-9
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-10
SAFETY
AVOID TIPPING
To avoid tipping:
Be extra careful before operating on a grade.
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
Reduce swing speed as necessary when
swinging loads.
S025-E02B-0495
SA-11
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-12
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position.
Close windows, roof vent, and cab door. SA-390
033-E02B-0390
SA-13
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
flammable.
034-E01A-0496 SA-019
SA-14
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-15
SAFETY
WARN OTHERS OF SERVICE WORK
SA-287
S501-E01A-0287
jack.
519-E01A-0527
502-E01A-0026 SA-026
SA-16
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-17
SAFETY
PREVENT BURNS
505-E01B-0498
506-E01A-0019
SA-18
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E01A-0499 SA-044
SA-19
SAFETY
PREVENT FIRES
Clean up Flammables:
S508-E05B-0019
SA-20
SAFETY
Check Emergency Engine Stop Switch:
S518-E01A-0393
SA-21
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016 SA-016
510-E01B-0030
SA-22
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with 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.
511-E01A-0029
512-E01B-0032
SA-23
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
SA-24
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Check the MSDS before you start any job using a SA-309
S515-E01A-0309
S516-E01A-0226
SA-25
SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
S517-E01A-0435 SA-435
SA-26
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shuttle Valve
Group 10 Solenoid Valve
Group 11 Oil Cooler Fan Motor
Group 12 Compressor Drive Motor
Group 13 Air Conditioner
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Travel Brake Valve
Group 4 Drive Tumbler
Group 5 Center Joint
Group 6 Adjuster Cylinder
Group 7 Front Idler
Group 8 Upper and Lower Roller
Group 9 Track Shoes
Group 10 Accumulator
Group 11 Welding Repair Procedure
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 General Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others(Upperstructure)
Group 3 Electrical System Group 7 Others(Undercarriage)
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology ......... W1-1-7
141W-1-1
(Blank)
141W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Thoroughly wash the machine before bringing it into To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassembling instructed.
/ assembling procedures beforehand, to help avoid If a part or component cannot be removed after
incorrect disassembling of components as well as removing its securing nuts and bolts, do not
personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. Orderly arrange disassembled parts. Mark and
tag them as necessary.
The machine model, machine serial number, and Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). Inspect the contact or sliding surfaces of
Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
Capacities and condition of lubricants. Measure and record the degree of wear and
Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling Bleeding Air from Hydraulic System
Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic
clean and dry.
motor housing, damage to the
If an anti-corrosive agent has been used on a
motor may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
Utilize matching marks when assembling. trapped in the cylinder tube, dam-
Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the
plug.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic Circuit
T142-05-03-008
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
uneven wear.
b b
a=b a b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
Allowable Limit
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
W1-2-1
GENERAL / Tightening
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before in-
stalling and tightening swing bearing
mounting bolts and lower roller mounting
bolts.
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.2) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.4) (135) 140 (14.3) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.2) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.3) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (199) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (199) (1440) 750 (76.5) (550)
M36 55 27 3200 (326) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Spilt Flange
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W 105-01-01-010
W1-2-5
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 9
7 6
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
W1-2-10
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
Preparation
T142-05-03-008
Hexagon Wrench
W118-02-03-018
W1-3-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
VACUUM
2
1. Bleed air from hydraulic oil tank. 3
(Refer to Bleeding Air from Hydraulic Oil Tank on 1
page W1-3-1) Port
Hydraulic Oil
Tank
W141-01-03-001
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Disassemble Air Compressor
Dimensions of the Cab Glass ...............W2-1-1 Drive Pump and Pilot Pump ............. W2-4-64
Assemble Air Compressor
Group 2 Counterweight Drive Pump and Pilot Pump ............. W2-4-70
Remove and Install Counterweight .......W2-2-1 Maintenance Standard ....................... W2-4-74
Disassemble Lubrication Pump
Group 3 Main Frame for Pump Transmission..................... W2-4-76
Assemble Lubrication Pump
Remove and Install Main Frame ...........W2-3-1
for Pump Transmission..................... W2-4-78
Maintenance Standard ....................... W2-4-80
Group 4 Pump Device
Remove and Install Pump Device .........W2-4-1
Disassemble Main Pump ......................W2-4-6
Group 5 Control Valve
Remove and Install Control Valve ........ W2-5-1
Assemble Main Pump .........................W2-4-16
Disassemble Control Valve .................. W2-5-4
Maintenance Standard ........................W2-4-24
Assemble Control Valve ..................... W2-5-12
Disassemble Regulator
Disassemble and Assemble
for Main Pump ..................................W2-4-26
Main Relief Valve,
Assemble Regulator for Main Pump....W2-4-32
Overload Relief Valve ....................... W2-5-16
Components of 4-Spool Pump ............W2-4-39
Make-up Valve Construction .............. W2-5-18
Disassemble Oil Cooler Fan
Drive Pump .......................................W2-4-40
Assemble Oil Cooler Fan Group 6 Swing Device
Drive Pump .......................................W2-4-44 Remove and Install Swing Device ........ W2-6-1
Maintenance Standard ........................W2-4-50 Disassemble Swing Reduction Gear .... W2-6-4
Disassemble Regulator Assemble Swing Reduction Gear....... W2-6-10
for Oil Cooler Fan Drive Pump ..........W2-4-52 Disassemble Swing Motor.................. W2-6-18
Assemble Regulator Assemble Swing Motor....................... W2-6-22
for Oil Cooler Fan Drive Pump ..........W2-4-58 Maintenance Standard ....................... W2-6-26
Disassemble and Assemble
Valve Unit ......................................... W2-6-28
141W-2-1
Group 7 Pilot Valve Group 12Compressor Drive Motor
Remove and Install Remove and Install
Front/Swing Pilot Valve .......................W2-7-1 Compressor Drive Motor .................. W2-12-1
Remove and Install Travel and Disassemble Compressor
Bucket Open/Close Pilot Valve............W2-7-3 Drive Motor ...................................... W2-12-4
Pilot Line Connection ............................W2-7-6 Assemble Compressor Drive Motor.... W2-12-6
Disassemble Front/Swing Pilot Valve....W2-7-8
Assemble Front/Swing Pilot Valve ......W2-7-10 Group 13 Air Conditioner
Disassemble Travel Work after Replacing Component ...... W2-13-1
Bucket Open/Close Pilot Valve..........W2-7-14 Add Compressor Oil ........................... W2-13-1
Assemble Travel Charge Air Conditioner
Bucket Open/Close Pilot Valve..........W2-7-16 with Refrigerant ................................ W2-13-2
141W-2-2
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Unit: mm
Material: JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent
NOTE: 1 mm = 0.03937 in
1378 1.5
1 6
4-R91
7
1
Laminated glass
Color : Transparent
1679
+2.0
-0
Thickness : 10 mm
Chamfer all fringe Corners
2
5
3
4
W146-02-01-002
W117-02-01-002
13691.5
4-R61
4-R61
2
3
Tempered glass
Color : Bronze Tempered glass
Thickness : 5 mm Color : Bronze
7691.0 Thickness : 5 mm
Chamfer all fringe Corners
Chamfer all fringe
917 1.0 Corners
W117-02-01-004
1256 1.5 4331.0
W117-02-01-003
W2-1-1
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