HITACHI ZAXIS 50U-2 EXCAVATOR Service Repair Manual by 163633

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      

INTRODUCTION

ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. The Operator s Manual The Parts Catalog

Operation Manual of the Engine Parts Catalog of the Engine Hitachi Training Material

MANUAL COMPOSITION This manual consists of two portions: the Technical Manual and the Workshop Manual. Use the manuals according to purpose. Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

PAGE NUMBER Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. NOTE: Indicates supplementary technical information or know-how.

UNITS USED 2

SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N Nm Nm

Into in ft US gal US qt yd3 lb kgf lbf kgf m lbf ft

Example : 24.5 MPa (250 kgf/cm , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees.

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Quantity Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW C km/h min-1 L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP F mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 C 1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.

SA-688

UNDERSTAND SIGNAL WORDS On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. Some safety signs don t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

CAUTION also calls attention to safety messages in this manual. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. NOTE indicates an additional explanation for an element of information.

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS Carefully read and follow all safety signs on the machine as well as all safety messages in this manual. Safety signs must be installed, maintained and replaced if damaged. If a safety sign or this manual is damaged or missing, order a replacement from your nearest Hitachi dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

Allow only properly trained, qualified, authorized personnel to operate the machine.

SA-003

Learn how to correctly operate and service the machine. Keep your machine in proper working condition. Always operate the machine within the specification. Unauthorized modifications of the machine may impair the functions and/or safety and affect machine life and the warranty will become void.

The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every possible hazardous situation you may encounter. If you have any questions concerning safety, you should first consult your supervisor and/or your nearest Hitachi dealer before operating or performing maintenance work on the machine.

PREPARE FOR EMERGENCIES Be prepared if a fire starts or if an accident occurs. Keep a first aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached on the fire extinguisher and use it properly. To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. Establish emergency procedure guidelines to cope with any fire or accidents which may occur. Keep emergency numbers for doctors, ambulance service, hospitals, and fire department posted near your telephone.

SA-2

SA-437

SAFETY WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety belt Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

INSPECT MACHINE DAILY If any abnormality is found, be sure to repair it immediately before operating the machine. In the walk-around inspection, be sure to cover all points described in the PRE-START INSPECTION chapter in the operator s manual.

SA-435

SA-3

SAFETY TIDY UP INSIDE CAB Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring. Remove mud and/or oily material from the shoe soles before entering the cab. If pedals are operated without removing mud or oily matter, the foot may slip off the pedal, possibly creating a hazardous situation. Do not leave parts and/or tools around the operator s seat. Do not keep a transparent water bottle in the cab. The transparent water bottle may concentrate the sun light like a lens, possibly causing a fire. Do not wear radio or music headphones and do not use a cell phone while traveling or operating the machine. Never allow hazardous materials such as combustible and/or explosive material in the cab. Do not leave a lighter in the cab. If the temperature in the cab increases, the lighter may explode.

USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine. Maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. In case adhered slippery material such as oil, grease, or mud is present on steps, handrails, or platforms, thoroughly remove such material.

SA-4

SA-439

SAFETY ADJUST THE OPERATOR'S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to mis-operation of the machine. The seat should be adjusted whenever the operator for the machine changes. The operator should be able to fully depress the pedals and to correctly operate the control levers with his back firmly against the seat back. If not, readjust the seat forward or backward, and check again.

SA-378

FASTEN YOUR SEAT BELT If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. Be sure to remain seated with the seat belt securely fastened whenever operating the machine. Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Replace the seat belt at least once every 3 years regardless of appearance

SA-5

SA-237

SAFETY MOVE AND OPERATE MACHINE SAFELY Always be aware that there is a potential danger around the machine while operating the machine. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm and horn in working condition (if equipped). Before starting to move or operate the machine, sound the travel alarm and horn to alert bystanders. Use a signal person when moving, swinging, or operating the machine in congested areas. Locate the signal person so that the operator can always witness the signal person. Coordinate the meanings of all safety signs, hand signals and marks before starting the machine. Appoint a person who is responsible to make a signal and/or guidance. Never allow any persons or obstacles to enter the machine operation areas. Use appropriate illuminations.

SA-6

SA-1291

SAFETY OPERATE ONLY FROM OPERATOR'S SEAT Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator's seat. NEVER start the engine while standing on the tracks or on ground. Do not start engine by shorting across starter terminals. A hazardous situation may be created and/or possible damage to the machine may result.

SA-444

Before starting the engine, confirm that all control levers are in neutral.

JUMP STARTING Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. If the engine must be jump started, be sure to follow the instructions shown in the OPERATING THE ENGINE chapter. The operator must be seated in the operator s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. Never use a frozen battery. Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-032

KEEP RIDERS OFF MACHINE Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator s view, resulting in the machine being operated in an unsafe manner. Only allow the operator is allowed on the machine. Keep riders off.

SA-1292

SA-7

SAFETY INVESTIGATE JOB SITE BEFOREHAND When working at the edge of an excavation or on a road shoulder, the machine could tip over due to collapse of the ground, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. Make a work plan. Use machines appropriate to the work and job site. Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders. When working on an incline or on a road shoulder, employ a signal person as required. Never allow bystanders to enter the working area such as swing radius or traveling range. Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist. When the footing is weak, reinforce the ground before starting work. When working on frozen ground, be extremely alert. As ambient temperatures rise, footing may become loose and slippery. When operating the machine near open flame, sparks, and/or dead grass, a fire may easily break out. Use special care not to cause a fire.

SA-8

SA-1293

SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES In case more than one machine is operated in the same job site, accidental collision between machines may cause serious injury or death. For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person s directions. SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal/lever operation may result in serious injury death. Before driving the machine, confirm the position of the undercarriage in relation to the operator s position. If the travel motors are located towards the front of the cab, the machine will move in the reverse direction when travel pedals/levers are operated. SA-1294

SA-9

SAFETY DRIVE MACHINE SAFELY Driving the machine in the incorrect direction may result in serious injury or death and/or severe damage to property.

Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to travel.

Avoid passing over any obstructions. Failure to do so may cause soil, rock fragments and/or metal pieces to be scatter around the machine. Keep bystanders away from the machine.

SA-1295

Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death. When traveling up or down a grade, keep the bucket in the direction of travel, approximately 200 to 300 mm (8 to 12 in) (A) above the ground so that lowering the bucket onto the ground can quickly stop the machine. If machine starts to skid or becomes unstable, lower the bucket immediately. Traveling across the face of slope or steering on a slope may cause the machine to skid or to turnover. If the direction must be changed on a slope, first move the machine to level ground, then, change the traveling direction to ensure safe operation.

A SA-1296

SA-441

SA-442

SA-10

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS Death or serious injury may result if you attempt to mount or try to bodily stop a moving machine. Park the machine in compliance with the safe parking procedures described on page S-15 to prevent the machine from running away.

Â&#x2022; Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park on a grade.

Â&#x2022; Park a reasonable distance from other machines.

SA-1297

SA-11

SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

Keep the travel alarm in working condition (if

equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

SA-383

USE A SIGNAL PERSON WHEN BACKING UP IF

YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.

No machine motions shall be made unless signals are clearly understood by both signalman and operator.

Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibility for signaling.

Keep windows, mirrors, and lights clean and in good condition.

Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

Read and understand all operating instructions in the operator s manual.

021-E01A-0494-8

SA-12

SA-384

SAFETY KEEP PERSONNEL CLEAR FROM WORKING AREA If a person is present near the operating machine, the person may come in contact with the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

Make sure that no personnel other than the signal

person or no obstacles are present in the working area before operating the machine.

SA-667

NEVER POSITION BUCKET OVER ANYONE Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

Never allow the bucket to pass over anyone to avoid personal injury or death.

SA-668

AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a panic. Lowering the front attachment may be safer in most cases.

SA-1300

SA-13

SAFETY AVOID TIPPING The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade.

Prepare machine operating area flat. Keep the bucket low to the ground and close to the machine.

Reduce operating speeds to avoid tipping or 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

SA-1301

loads.

Be careful when working on frozen ground.

Temperature increases will cause the ground to become soft and make ground travel unstable.

025-E01A-0540-4

NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious injury or death.

SA-1302

SA-14

SAFETY DIG WITH CAUTION Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

Before digging check the location of cables, gas lines, and water lines.

Keep the minimum distance required, by law, from cables, gas lines, and water lines.

If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

Contact your local diggers hot line if available in your

SA-672

area, and/or the utility companies directly. Have them mark all underground utilities.

OPERATE WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

Take care to avoid hitting overhead obstacles with the boom or arm.

SA-673

AVOID POWER LINES Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length.

Check and comply with any local regulations that may apply.

Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-15

SA-1305

SAFETY DO NOT USE FOR CRANING OPERATIONS NEVER use the machine for craning operations. If the machine is used for craning operations, the machine may tip over and/or lifted load may fall, possibly resulting in serious injury or death. This machine has been exclusively designed to engage in excavation and loading works. This machine is not equipped with any of the necessary safety devices that could allow the machine to be used for craning operation.

SA-014

PROTECT AGAINST FLYING DEBRIS If flying debris such as soil, rock fragments or metal pieces hit eyes or any other part of the body, serious injury may result.

Â&#x2022; Guard against such injuries when working in a job site where possibility of flying pieces of metal or debris exist, or when removing or installing pins using a hammer; wear goggles or safety glasses.

Â&#x2022; Keep bystanders away from the working area before striking any object.

SA-432

SA-16

SAFETY PARK MACHINE SAFELY Unless the machine is not correctly parked, any hazardous situations such as running away of the machine or damage by vandalism may result, causing the machine to operate unsafely when the engine is re-started. Follow instructions described below when parking the machine.

Park the machine on solid level surface to prevent the machine from running away.

Lower the bucket and/or blade to the ground.

SA-1306

Pull the lock lever to the LOCK position. Turn the auto-idle switch (optional) OFF. Failure to do so may create a hazarduos condition as the engine speed may unexpectedly increase.

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.

Before leaving the machine, close all windows, roof vent, and cab door. Lock all access doors and compartments

HANDLE FLUIDS SAFELY --- AVOID FIRES Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

Do not refuel the machine while smoking or when near open flame or sparks.

Always stop the engine before refueling the machine. Fill the fuel tank outdoors. All fuels, most lubricants, and some coolants are flammable.

SA-018

Store flammable fluids well away from fire hazards. Do not incinerate or puncture pressurized containers. Do not store oily rags; they can ignite and burn spontaneously.

SA-019

SA-17

SAFETY SAFETY TRANSPORTING The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed.

Be sure to observe local regulations when transporting the machine on public roads.

Provide an appropriate truck or trailer for transporting

SA-1307

the machine.

Be sure to have a signal person. Take the following precautions when loading/unloading the machine.

1. Select firm level ground. 2. Be sure to use a loading dock or ramp strong enough to support the machine weight. 3. Ramps must be sufficient in width, length, and strength. Be sure that the incline of the ramp is less than 15 degrees. 4. Loading docks must be sufficient in width and strength to support the machine and have a gradient of less than 15 degrees. 5. Be sure to turn the auto-idle switch (13) OFF.

6. Slowly drive the machine. 7. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 8. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 9. Wedge the front and rear of tracks. Securely fasten the machine to the trailer bed with chain or cables. 10. Do not operate any levers besides the travel levers when driving up or down the ramp. 11. Prevent possible injury from machine tipping while the upperstructure is rotating. 12. Keep the arm tucked under and rotate the upperstructure slowly for best stability. Refer to "transporting" chapter in operator s manual for details

SA-18

M1M7-01-028

SAFETY PRACTICE SAFE MAINTENANCE Inspection/maintenance work may produce hazardous situations by contacting and/or accessing a part of body to a moving, high pressure, and/or high temperature part of the machine. To avoid serious personal injury or death, follow the instructions described below.

Thoroughly coordinate the working procedures to be

taken hereafter with the co-workers before beginning work such as inspecting/servicing the machine, or replacing the attachiment .

Safely park the machine in accordance with the instructions for Park Machine Safely.

Keep the work area clean and orderly. Attach a DO NOT OPERATE tag in an easy-to-see

SA-028

location such as on a door or a control lever.

If moisture permeates into the electrical system,

malfunction and/or erroneous movement of the machine may result. Do not clean sensors, cable connectors, and the cab inside using water and/or steam.

Wait to begin to work until the engine and hydraulic oil temperatures have cooled down to the safety range.

In case inspection/maintenance must be performed

90 to 110

with the engine runnning, be sure to appoint an overseer.

Never lubricate or service the machine while moving it. Repair the cracked windowpane before servicing the

M1M7-04-006

machine. Failure to do so may cause personal injury.

Whe raising the machine above the ground using the

front attachment function, maintain the angle between the boom and the arm in the range of 90 to 110 . Never allow anyone to enter under the machine raised with the front attachment function.

In case working under the machine raised above the

ground is unavoidably required, securely hold the machine with stays or blocks strong enough to support the machine weight.

Never work under the raised bucket. Keep all parts in good condition and properly installed. Always use the specified tools correctly. Always use a clean tool.

SA-527

Fix any damage found immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris. When cleaning parts, use a non-combustible cleaning solvent. Never use an inflammable fluid such as dieasel fuel, or gasoline.

SA-19

SAFETY Disconnect battery ground cable ( ) before making

adjustments to electrical systems or before welding on the machine.

Sufficiently illuminate the work site. Use a

maintenance work light when working under or inside the machine.

Always use a work light protected with a guard. In

case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire. SA-037

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a

Do Not Operate tag in an easy-to-see place such as on the cab door or control lever.

Never attempt to operate the machine with a Do Not Operate tag attached.

Make it a rule for the inspection/service person to hold the engine start key during inspection/service work.

SA-287

SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first.

Always lower the attachment to the ground before you work on the machine.

If you must work on a lifted machine or attachment,

securely support the machine or attachment with stays or blocks strong enough to support the machine and/or attachment weight. SA-527

STAY CLEAR OF MOVING PARTS Contact with moving parts can cause serious injury or death due to amputation or entanglement.

To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

SA-20

SAFETY PREVENT PARTS FROM FLYING Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death.

Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES.

As pieces of parts may fly off, be sure to keep body and face away from the valve.

Travel reduction gears are under pressure.

As pieces of parts may fly off, be sure to keep body

SA-344

and face away from AIR RELEASE PLUG to avoid injury.

GEAR OIL is hot. Wait for gear oil to cool, then

gradually loosen the air release plug to release pressure.

STORE ATTACHMENTS SAFELY Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

Securely store attachments and implements to prevent falling accidents.

Keep children and bystanders away from storage areas.

SA-034

SA-21

SAFETY PREVENT BURNS Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

To prevent possible injury from hot spraying water,

stop the engine. Begine to work after the engine and radiator are sufficiently cooled

DO NOT remove the radiator cap until the engine is

cool. When opening, turn the cap slowly to the stop. Allow all pressure to be release before removing the cap.

SA-039

The hydraulic oil tank is pressurized. Again, be sure to release all pressure by slowly removing the cap.

Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also becomes hot during operation. The engine, hoses, lines and other parts become hot as well.

Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-22

SAFETY REPLACE RUBBER HOSES PERIODICALLY Rubber hoses that contain flammable fluids such as hydraulic oil or fuel under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by visual inspection alone.

Periodically replace the rubber hoses. (Refer to the Periodical Replacement Parts section in the operator s manual.)

Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

AVOID HIGH-PRESSURE FLUIDS Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that all connectors are completely connected before applying pressure.

Search for leaks with a piece of cardboard; take care

SA-031

to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

If an accident occurs, see a doctor familiar with this

type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-292

SA-044

SA-23

SAFETY PREVENT FIRES Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires, possibly resulting in personal injury or death.

Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts, for oil leaks.

Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

SA-019

Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes or hoses.

Check for Shorts: Short circuits can cause fires.

Clean and tighten all electrical connections. Check before each shift or after eight (8) to ten (10)

hours operation for loose, kinked, hardened or frayed electrical cables and wires.

Check before each shift or after eight (8) to ten (10)

hours operation for missing or damaged terminal caps.

DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

SA-24

SAFETY Precautions for Handling Flammables Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately.

Don t store flammable fluid near open flames. Don t burn or crush a pressurerized container. Don t store oily cloths. They are liable to catch fire. Don t wind easy-to-absorb-oil asbestos or glass wool around high-temperature parts such as a muffler or exhaust pipe.

Check Heat Shield Covers around Engine Compartment If the engine compartment heat shield cover becomes broken or lost, fire may break out.

If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the machine.

Check Key Switch: If fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day:

1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine hasstopped.

If any abnormalities are found, be sure to repair them before operating the machine.

SA-25

SAFETY EVACUATING IN CASE OF FIRE If fire breaks out during machine operation, evacuate the machine in the following way:

Stop the engine by turning the key switch to the OFF position.

Use a fire extinguisher if there is time. Exit the machine using handrails and/or steps. In an emergency, if the cab door or front window can

not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method in the operator s manual.

SA-393

SS-1510

BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

SA-26

SAFETY PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and/or small fires.

Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

Grinding on the machine may create a fire hazard. Store flammable objects in a safe place before starting grinding. After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-818

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids.

Remove flammable fluids thoroughly with

nonflammable solvent before welding or flame cutting pipes or tubes that contained flammable fluids.

SA-27

SA-030

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.

Remove paint before welding or heating. Avoid potentially toxic fumes and dust. Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

Allow fumes to disperse at least 15 minutes after welding or heating.

SA-029

Use attention to the following points when removing paint.

1. If you sand or grind paint, avoid breathing the dust which is created. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. 3. Remove solvent or paint stripper containers and other flammable material from area.

PREVENT BATTERY EXPLOSIONS Battery gas can explode.

Keep sparks, lighted matches, and flame away from the top of battery.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warm the battery to 16 C (60 F) first.

Do not continue to use or charge the battery when the electrolyte level is lower than specified. Explosion of the battery may result.

When a terminal become loose, it may induce sparks. Securely tighten all terminals.

Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If electrolyte is splashed into eyes, flush your eyes continuosly with water for about 15 minutes. Seek medical attention immediately.

Be sure to wear eye protection when checking electrolyte specific gravity.

SA-28

SA-032

SAFETY PRECAUTIONS FOR HANDLING REFRIGERANT If refrigerant is splashed into eyes or spilled onto skin, blindness or a cold contact burn may result.

Refer to the precautions described on the refrigerant container for handling refrigerant.

Use a recovery and recycling system to avoid venting refrigerant into the atmosphere.

Never allow the skin to directly come in contact with refrigerant.

SA-405

HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, electrolyte, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. Then follow the correct procedures and use recommended equipment.

SA-309

See your nearest Hitachi dealer for MSDS.

SA-29

SAFETY SIGNS DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

When draining fluid, use a leakproof container with a capacity larger than the drained fluid volume to receive it.

Do not pour waste onto the ground, down a drain, or into any water source.

Inquire on the proper way to dispose of harmful waste such as oil, fuel, coolant, brake fluid, filters, and batteries from your local environmental or recycling center.

SA-226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER After maintenance or repair work is complete, confirm that:

The machine is functioning properly, especially the safety systems.

Worn or damaged parts have been repaired or replaced

SA-435 S517-E01A-0435

SA-30

SECTION AND GROUP CONTENTS

WORKSHOP MANUAL

SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank Group 5 Floor-Tilting Device

SECTION 2 UPPERSTRUCTURE Group 1 Canopy Group 2 Counterweight Group 3 Pump Device Group 4 Control Valve Group 5 Swing Device Group 6 Pilot Valve Group 7 Solenoid Valve Group 8 Revolution Sensing Valve Group 9 Auxiliary Flow Selector Valve (Optional)

SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track

SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

SECTION 5 ENGINE

TECHNICAL MANUAL

SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Revolution Sensing Valve Group 3 Swing Device Group 4 Control Valve Group 5 Pilot Valve Group 6 Travel Device Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Troubleshooting A Group 3 Troubleshooting B Group 4 Troubleshooting C Group 5 Electrical System Inspection

SECTION 1

GENERAL INFORMATION CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology ........ W1-1-7

Group 2 Tightening Tightening Torque Specifications .............. W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5 Periodic Replacement of Parts ............. W1-2-10

Group 3 Painting Painting .................................................. W1-3-1

Group 4 Bleeding Air Bleed Air from Hydraulic Oil Tank ........... W1-4-1

Group 5 Floor-Tilting Device Floor-Tilting Device Operetion Procedure............................................. W1-5-1 Procedure for Floor Tilting up ................. W1-5-2 Procedure for Floor Tilting down ............. W1-5-4

1M9W-1-1

(Blank)

1M9W-1-2

GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling Clean the Machine

Precautions for Disassembling

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

To prevent dirt from entering, cap or plug the removed pipes. Before disassembling, clean the exterior of the components and place on a work bench. Before disassembling, drain gear oil from the reduction gear. Be sure to provide appropriate containers for draining fluids. Use matching marks for easier reassembling. Be sure to use the specified special tools, when instructed. If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. Orderly arrange disassembled parts. Mark and tag them as necessary. Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. Measure and record the degree of wear and clearances.

Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. The machine model, machine serial number, and hour meter reading. Reason for disassembly (symptoms, failed parts, and causes). Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants. Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

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 any damage. If any damage is found, repair or replace part. Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. Be sure that liquid-gasket-applied surfaces are clean and dry. If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. Utilize matching marks when assembling. Be sure to use the designated tools to assemble bearings, bushings and oil seals. Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine. Bleeding Air from Hydraulic Pump 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 engine 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. Bleeding Air from Travel Motor / Swing Motor With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.

W1-1-2

GENERAL / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic Circuit After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. Reposition the front attachment to check hydraulic oil level. Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-3

M1M7-05-024

GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. B

(2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.

tears,

W105-03-05-019

breaks,

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.

Correct

Incorrect

(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

W105-03-05-020

Correct

Incorrect

b a=b

b a b W110-03-05-004

W1-1-4

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. Lower the temperature of the lifted load to lower than 100 C (212 F). If unavoidably lifting a load with a temperature of 100 C (212 F) or more, reduce the load weight. Do not lift acid or alkali chemicals. Take care not to allow the sling to become wet. The load may slip. When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. Avoid using twisted, bound, connected, or hitched slings. Do not place any object on twisted or bent slings. (Refer to the right illustration.) When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. Store the nylon slings indoors so they won t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-5

W162-01-01-009

GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

Broken Sewing Thread

W162-01-01-002

Scuffing

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples 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

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY Standard 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification.

Allowable Limit 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the Allowable Limit .

W1-1-7

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

GENERAL INFORMATION / Tightening TIGHTENING TORQUE SPECIFICATIONS No. 1. 2. 3. 4.

Descriptions Engine cushion rubber mounting bolt Engine bracket mounting bolt (Front) Hydraulic oil tank mounting bolt Fuel tank mounting nut Metal face seal Union joints fitting for hydraulic for hydraulic hoses and piping hoses and pipes ORS

6. 7. 9. 10.

Pump mounting bolt Pump cover mounting bolt Control valve mounting bolt Control valve base mounting bolt Swing device mounting bolt Battery mounting nut

11.

Canopy mounting bolt

12.

Cab mounting bolt

14. 15. 16. 17.

Swing bearing Upperstructure mounting bolt Undercarriage Travel device mounting bolt Sprocket mounting bolt Upper roller mounting bolt Lower roller mounting bolt

18.

Cover mounting bolt

19.

Counterweight mounting bolt

20.

Front pin lock plate bolts

21. 22

Side-cutter mounting bolts Track roller guard mounting bolt

13.

Bolt Dia. mm 12 10 12 10 7/16-20UNF

QÂ&#x2019;ty 4 8 4 3

9/16-18UNF 3/4-16UNF 1-1/16-12UNF 1-5/16-12UNF 9/16 UNF 11/16 UNF 13/16 UNF 12 10 10 10 16 6 12 10 12 10 12 12 14 14 16 14 6 8 10 24 10 12 14 16 18 14 16

NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients. (2) Remove rust, dirt, and dust before installing fasteners.

W1-2-1

2 8 4 4 8 2 5 5 5 5 27 24 24 24 2 16

6 12

Wrench Size mm 19 17 19 17 17 19 22 27 36 41 19 22 27 10 (Socket) 17 17 17 24 10 19 17 19 17 19 19 22 22 24 22 10 13 17 36 17 19 22 24 27 22 24

Nm 88 49 88 20 24.5 29.5 39 93 175 205 44 74 103 88 49 49 49 205 5 88 49 88 49 108 108 175 175 231 177 5 9.8 49 930 49 88 137 205 390 175 265

Torque (kgf m) (9) (5) (9) (2) (2.5) (3) (4) (9.5) (18) (21) (4.5) (7.5) (10.5) (9) (5) (5) (5) (21) (0.5) (9) (5) (9) (5) (11) (11) (18) (18) (23.5) (18) (0.5) (1) (5) (95) (5) (9) (14) (21) (40) (18) (27)

(lbf ft) (65) (36) (65) (15) (18) (22) (29) (69) (129) (151) (32) (55) (76) (65) (36) (36) (36) (101) (3.5) (65) (36) (65) (36) (80) (80) (130) (130) (170) (130) (3.5) (7) (36) (398) (36) (65) (101) (152) (290) (130) (196)

GENERAL INFORMATION / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components. Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Bolt Dia.

Wrench Size

Hexagon Wrench Size

M552-07-091

M552-07-090

M157-07-225

Socket Bolt Nm

(kgf m)

(lbf ft)

(kgf m)

(lbf ft)

(kgf m)

(3.1)

(22)

(2.0)

(15.0)

(1.0)

(7.4)

M10

(6.6)

(48)

(5.1)

(37)

(2.0)

(15.0)

M12

110

(11.0)

(81)

(9.2)

(66)

(3.6)

(26.0)

M14

180

(18.5)

(135)

140

(14.0)

(103)

(5.6)

(41)

M16

270

(27.5)

(200)

210

(21.5)

(155)

(8.2)

(59)

M18

400

(41.0)

(295)

300

(30.5)

(220)

120

(12.0)

(89)

M20

550

(56.0)

(410)

400

(41.0)

(295)

170

(17.0)

(125)

M22

750

(76.5)

(550)

550

(56.0)

(410)

220

(22.5)

(162)

M24

950

(97.0)

(700)

700

(71.5)

(520)

280

(28.5)

(205)

M27

1400

(143)

(1030)

1050

(107)

(770)

400

(41.0)

(295)

M30

1950

(200)

(1440)

1450

(148)

(1070)

550

(56.0)

(410)

M33

2600

(265)

(1920)

1950

(200)

(1440)

750

(76.5)

(550)

M36

3200

(325)

(2360)

2450

(250)

(1810)

950

(97.0)

(700)

W1-2-2

(lbf ft)

GENERAL INFORMATION / 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 lubricant. 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 application. 5. Make sure that nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower

Tighten from center and diagonally

Tighten 1

1st to 4th

6 4

5 2

2nd to 3rd W105-01-01-003

W1-2-3

GENERAL INFORMATION / Tightening Service Recommendations for Split Flange IMPORTANT: 1. Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Do not bend it round

Bend along edge sharply

Nut and Bolt Locking 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 holes in the bolt and nut while tightening, not while loosening. Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction.

RIGHT

WRONG

RIGHT

Bend along edge sharply

RIGHT

WRONG

Loosen

W105-01-01-009

WRONG

Tighten

W105-01-01-010

W1-2-4

GENERAL INFORMATION / Tightening PIPING JOINT IMPORTANT: 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 application. Union Joint

Metal sealing surfaces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten nut (3) to specifications. 2. 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/disconnecting.

M202-07-051

Joint Body

37 30

Male Union Joint

Female Union Joint W105-01-01-017

Description 30 male

37 female

Wrench Size mm Union Nut 17 19 22 27 32 36 41 17 19 22 27 32 36 41

Wrench Size mm Hose Fittings 17 19 22 27 32 36 41 14 17 19 22 27 32 36

Tightening Torque N m (kgf m, lbf ft) 24.5 (2.5,18) 29.5 (3.0,22) 39 (4.0,28.5) 64 (6.5,47) 137 (14,101) 175 (18,129) 205 (21,151) 24.5 (2.5,18) 29.5 (3.0,22) 39 (4.0,28.5) 64 (6.5,47) 137 (14,101) 175 (18,129) 205 (21,151)

NOTE: Tightening torque of 37 male coupling without union is similar to tightening torque of 37 female.

W1-2-5

GENERAL INFORMATION / Tightening Piping Joint 1

Pipe Joint (Metal Joint) (Union Nut Wrench size 17 mm)

Metal sealing surfaces (3) (Metal) of pipe (2) and adapter (1) seal pressure oil. Take care not damage sealing surfaces when connecting / disconnecting pipe. Tightening Torque Chart Wrench Size (mm) Nm Tightening (kgf m) Torque (lbf ft)

M1M7-07-005

17 39 (4.0) (29) 7

O-ring Seal Joint

O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. IMPORTANT: 1. Be sure to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (8) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).

Wrench Size mm Union Nut 19 22 27 32 36 41 46

W1-2-6

Wrench Size mm Hose Fittings 17 19 22 27 30,32 36 41

Hose Fittings M104-07-033

Tightening Torque N m (kgf m, lbf ft) 29.5 (3.0,22) 69 (7.0,51) 93 (9.5,69) 137 (14,101) 175 (18,129) 205 (21,151) 205 (21,151)

GENERAL INFORMATION / Tightening Quick Coupler 1. Connection Procedure

While pulling and fully turning socket ring (1)

counterclockwise, insert socket ring (1) onto plug (3) until the end face of socket ring (1) comes in contact with plug (3). Release socket ring (1). Check that socket ring (1) is slightly move backward by the spring force and the coupler is held in position with balls (2). Be sure to check that socket ring (1) has been moved back fully to the right original position. 2. Disconnection Procedure

While pulling and fully turning socket ring (1)

counterclockwise, disconnect the coupler. As no check valve is provided in the coupler, take care that oil may flow out of the coupler when the coupler is disconnected. After the coupler is disconnected, plug the holes with the exclusively prepared plugs. CAUTION: Take care not to damage the joint surfaces when disconnecting or connecting the coupler. Before disconnecting or connecting the coupler, clean the coupler and its surroundings with a cleaning solvent and completely wipe off the cleaning solvent. Use extra care not to allow foreign matter such as dirt to enter the coupler. Disconnect or connect the coupler in the correct procedure. Sufficiently check that no oil leak is present after connecting the coupler. After connecting the coupler, check that that socket ring (1) has been moved back fully to the right original position.

W1-2-7

M1M7-07-006

GENERAL INFORMATION / Tightening Screw-In Connection PT

Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

Male Tapered Thread

Male Straight Thread W105-01-01-018

Wrench Size mm Hose Fittings 19 22 27 36 41 50 60

Male Tapered Thread Tightening Torque N m (kgf m, lbf ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5,25) 29.5 (3.0,21.5) 49 (5.0,36) 49 (5.0,36) 93 (9.5,69) 69 (7.0,51) 157 (16,116) 108 (11,80) 205 (21,151) 157 (16,116) 320 (33,235) 195 (20,144)

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

Application Procedure

W105-01-01-019

Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N m (0.45 kgf m, 3.25 lbf ft) Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft)

W1-2-8

M114-07-041

T-Bolt Type

Worm Gear Type

M114-07-043

M114-07-042

GENERAL INFORMATION / Tightening Connecting Hose

RIGHT

WRONG

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. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked. If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects.

W105-01-01-011

RIGHT

WRONG Rubbing Against Each Other

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing Against Each Other W105-01-01-013

WRONG

Rubbing Against Each Other

RIGHT

Clamp W105-01-01-014

W1-2-9

GENERAL INFORMATION / Tightening PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace if necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, if necessary. Consult your authorized dealer for correct replacement.

Periodic Replacement Parts Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Heater hose (Heater to engine) Engine Engine rubber vibration insulator Floor mount rubber Pump coupling Pump suction hose Pump delivery hose Base Machine Swing hose Auxiliary hose Hydraulic Oil cooler hose (C/V to oil cooler) System Boom cylinder line hose Arm cylinder line hose Front Attachment Bucket cylinder line hose Pilot hose NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.

W1-2-10

Replacement Interval Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 5 years or 5000 hours Every 5 years or 5000 hours Every 5 years or 5000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours Every 2 years or 4000 hours

GENERAL / Painting PAINTING

Section Upperstructure

Undercarriage

Front attachment

Surfaces to Be Painted Outer cover (Right, Left, Rear and Top)

Painting Color YR1-01 [TAXI yellow]

Skirt (Front, Right and Left)

SP-424 [Dark gray]

Main frame

SP-424 [Dark gray]

SP-424 [Dark gray] Inside (Oil, Fuel tank) Canopy (Pole) SP-424 [Dark gray] Stay ( Left) Black Lever (Travel, Blade) N-10 [N1.0] Pedal (Travel, Boom swing) SP-424 [Dark gray] Floor plate, Seat base SP-424 [Dark gray] Console (Right, Left) SP-424 [Dark gray] Counterweight SP-424 [Dark gray] Track frame (Including idler, upper and SP-424 [Dark gray] lower roller) Swing bearing Black Blade (Including cylinder) SP-424 [Dark gray] Boom, Arm, Bucket and Link YR1-01 [TAXI yellow] (Including cylinder) Swing post (Including cylinder) SP-424 [Dark gray]

Dark Gray

Cab Type

Black Dark Gray Dark Gray

TAXI Yellow

Dark Gray

W1M9-01-03-001

Black

TAXI Yellow

Dark Gray

W1-3-1

Dark Gray

TAXI Yellow

GENERAL / Painting (Blank)

W1-3-2

GENERAL / Bleeding Air BLEED AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Do not turn the cap on hydraulic oil tank quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. Preparation 1. Park the machine on a solid, level surface. Lower the front attachment onto the ground. 2. Stop the engine. Loosen cap (1) on hydraulic oil tank (2) and release any remaining pressure.

M1M7-05-024

3. Remove cap (1) on hydraulic oil tank (2).

1 2

4. Install a vacuum pump to the hole without cap (1). Operate the vacuum pump and maintain negative pressure in the hydraulic oil tank. Run the vacuum pump continuously while working.

W1M9-01-04-001

Vacuum Pump Hose

Adapter

W1M9-01-04-002

W1-4-1

GENERAL / Bleeding Air (Blank)

W1-4-2

GENERAL / Floor-Tilting Device FLOOR-TILTING PROCEDURE

DEVICE

OPERATION

Preparation Park the machine in a flat and solid place. Lower the blade. Roll-in the arm and bucket, and put them on the front wooden block or something. CAUTION: Be careful because interference of the boom and canopy (cab) takes place unless the front end attachment is lowered in advance. M1M7-07-060

Close the door of the cab (optional).

W1-5-1

GENERAL / Floor-Tilting Device PROCEDURE FOR FLOOR TILTING UP CAUTION: If tilting up operation is made with the door open, it interferes with the cover (3). 1. Remove two bolts (2), and remove (3) from the canopy or cab (1). : 17 mm IMPORTANT: Near bolts (4), two bolts for fixing the canopy or cab (1) are fitted. Never remove these two bolts in tilting up operation. A bolt never to be removed can be identified by the attached cap or red paint.

2 3 4

4-Pillar Canopy

M1M7-07-061

2. Remove three bolts (4) from the canopy or cab (1). : 19 mm

2-Pillar Canopy

Not to be removed

M1M7-07-063

Cab

Not to be removed

M1M7-07-062

M1M7-07-064

Not to be removed

W1-5-2

GENERAL / Floor-Tilting Device IMPORTANT: The operating torque of adjuster screw (5) is 24.5 N m (2.5 kgf m) or lower. In case larger torque is required, it is probable that bolts (4) remain unremoved. Re-check from this perspective. 3. Turn adjuster screw (5). Tilt the canopy or cab (1) assembly toward front. : 17 mm 4. Turn adjuster screw (5) clockwise until disc (6) on the side face of the tilting device moves to the farthest end.

M1M7-07-065

2-Pillar / 4-Pillar Canopy

CAUTION: Do not tilt up cab (1) as far as the striped region. If done so, cab (1) tilts forward because the center of gravity overhangs the balancing point, which is dangerous.

M1M7-07-066

Cab

5. In cab (1) version machines, stop tilting up 50 mm before the farthest end [before the striped region (6)].

6 50 mm W1M9-01-05-001

IMPORTANT: Do not make tilting up operation by other means (e.g. by crane) than the tilting device. The tilting device or floor could be damaged otherwise. 6. In case of work done lying under the floor, put a support at the opening space of the raised floor for security.

Support

M1M7-07-067

W1-5-3

GENERAL / Floor-Tilting Device PROCEDURE FOR FLOOR TILTING DOWN CAUTION: Do not lower the floor abruptly. If adjuster screw (5) is rotated abruptly in lowering the floor, the floor trembles enormously, which is dangerous. 1. Slowly turn adjuster screw (5) anticlockwise. : 17 mm

8 9

2. Turn adjuster screw (5) counterclockwise until the farthest end contacts receiver seat (7).

CAUTION: After the floor has been lowered completely, if adjuster screw (5) is kept turned, it will not be turned any longer when unscrewed by about 15 mm because washer (10) touches pin (11). Be careful not to turn adjuster screw (5) further because washer (10) deforms and gets damaged, causing fall of bolt (12). 3. When the floor has been lowered completely, adjuster screw (5) is drawn. Make adjustment so that the clearance between collar (8) of adjuster screw (5) and contact face (9) becomes 2 to 5 mm.

W1-5-4

5 10

M1M7-07-068

W1M9-01-05-002

GENERAL / Floor-Tilting Device 4. Install the canopy or cab (1) with three bolts (4). : 19 mm : 90 N m (9.2 kgf m)

2-Pillar Canopy

M1M7-07-063

4-Pillar Canopy

Cab

M1M7-07-062

M1M7-07-064

W1-5-5

GENERAL / Floor-Tilting Device (Blank)

W1-5-6

MEMO .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................

SECTION 2

UPPERSTRUCTURE CONTENTS Group 1 Canopy

Group 6 Pilot Valve

Remove and Install Canopy.................... W2-1-1

Remove and Install Front Pilot Valve ...... W2-6-1 Remove and Install Travel Pilot Valve ..... W2-6-3

Group 2 Counterweight Remove and Install Counterweight ......... W2-2-1

Remove and Install Blade Pilot Valve...... W2-6-7 Remove and Install Boom Swing Pilot Valve ...................... W2-6-9

Group 3 Pump Device Remove and Install Pump Device ........... W2-3-1 Disassemble Pump Device ................... W2-3-4 Assemble Pump Device ......................... W2-3-6 Maintenance Standard.......................... W2-3-10

Group 4 Control Valve Remove and Install Control Valve ........... W2-4-1 Disassemble And Assemble Control Valve ...................................... W2-4-6 Remove and Install Relief Valve and Make-up Valve ........................... W2-4-12 Disassemble and Assemble Body ....... W2-4-14 Disassemble Unload Section ................ W2-4-16 Assemble Unload Section..................... W2-4-18 Disassemble and Assemble Spool ........ W2-4-20 Disassemble and Assemble Boom Anti-Drift Valve ........................ W2-4-22 Disassemble and Assemble Shuttle Valve and Pressure Compensation Valve .......... W2-4-24

Group 5 Swing Device Remove and Install Swing Device........... W2-5-1

Disassemble Front Pilot Valve .............. W2-6-12 Assemble Front Pilot Valve ................... W2-6-16 Disassemble Travel Pilot Valve ............. W2-6-20 Assemble Travel Pilot Valve ................. W2-6-24 Disassemble Pilot Valves for Boom Swing, Blade and Auxiliary............................ W2-6-30 Assemble Pilot Valves for Boom Swing, Blade and Auxiliary............................ W2-6-32

Group 7 Solenoid Valve Remove and Install 2-Unit Solenoid Valve .......................... W2-7-1 Disassemble 2-Unit Solenoid Valve ........ W2-7-6 Assemble 2-Unit Solenoid Valve ............. W2-7-8 Remove and Install 1-Unit Solenoid Valve ........................ W2-7-10 Structure of 1-Unit Solenoid Valve ...... W2-7-12

Group 8 Revolution Sensing Valve Remove and Install Revolution Sensing Valve.................... W2-8-1 Disassemble Revolution Sensing Valve .. W2-8-4

Disassemble Swing Device .................... W2-5-6

Assemble Revolution Sensing Valve ....... W2-8-6

Assemble Swing Device ......................... W2-5-8

Group 9 Auxiliry Flow Selector Valve (Optional)

Disassemble Swing Motor .................... W2-5-14 Assemble Swing Motor ......................... W2-5-16 Maintenance Standards ........................ W2-5-20

Remove and Install Auxiliary Flow Selector Valve .............. W2-9-1 Disassemble Auxiliary Flow Selector Valve............................. W2-9-4 Assemble Auxiliary Flow Selector Valve............................. W2-9-6

1M9W-2-1

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