Page 1

EX1100-3 Workshop Manual


SECTION 1

GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1

Group 2 Tightening Torque Specification ............................... W1-2-1 Torque Chart .......................................... W1-2-3 Piping joint ............................................. W1-2-6

142W-1-1


(Blank)

142W-1-2


GENERAL INFORMATION / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it 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.

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.

• Inspect the Machine Be sure to thoroughly understand all disassembling/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.

• Precautions for Assembling

W1-1-1

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • 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 tools are missing.


GENERAL INFORMATION / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and install ation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

• Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • 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.

• 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.

W1-1-2

M104-07-021


GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions

A

1. In general, replace the floating seal with a new one. If the floating 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. (2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear.

B W105-03-05-019

(3) Check O-ring (B) for tears, breaks, deformation or hardening. 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, as dust on them tends to enter the floating seal when installing it. (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 idler 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

Incorrect

Correct

C a

a

A B

b

a=b

b

aŇ?b W110-03-05-004

W1-1-3


GENERAL INFORMATION / Precautions for Disassembling and Assembling (Blank)

W1-1-4


GENERAL INFORMATION / Tightening Torque TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia mm

Q'ty

Engine cushion rubber mounting bolt (F) Engine cushion rubber mounting bolt (R)

22 33

2 2

Engine bracket mounting bolt (F) Engine bracket mounting bolt (R)

18 27

Radiator mounting bolt Hydraulic oil tank mounting bolt

Descriptions

Wrench Size mm

Torque N⋅m

kgf⋅m

lbf⋅ft

32 50

740 2550

75 260

540 1880

2 12

27 41

390 1030

40 105

290 760

27

4

41

1030

105

760

20

8

30

540

55

400

Fuel tank mounting bolt

20

8

30

540

55

400

ORS fittings for hydraulic hoses and piping

1-7/16-12UNF 1-11/16-12UNF

41 50

205 340

21 35

152 255

Pump transmision mounting bolt

1/2-13UNF

19

118

12

87

12

Hexagon bar wrench 17

540

55

400

14

2

22

137

14

101

20

4×2

30

390

40

290

Swing device mounting bolt

27

16×2

41

1370

140

1010

Swing motor mounting bolt:

12

12×2

19

88

9

65

Battery mounting bolt

12

2

19

34

3.5

25.5

Cab mounting bolt

16

8

24

265

27

195

Cab-bed mounting bolt

16

34 (B/H) 58 (L/D)

24

205

21

152

Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage

36 36

52 50

55 55

2750 2750

280 280

2030 2030

Travel device mounting bolt

27

52

41

1370

140

1010

Travel motor mounting bolt

18

8

27

295

30

215

Sprocket mounting bolt

27

60

41

1370

140

1010

Pump mounting bolt

20

Gear pump mounting bolt Control valve mounting bolt

Upper roller mounting bolt

20

24

30

540

55

400

Lower roller mounting bolt

27

64

41

1370

140

1010

Track shoe mounting bolt

30

416

46

2840

290

2090

Track guard mounting bolt

27

28

41

1370

140

1010

Side frame mounting bolt

42

52

65

3920

400

2890

Counterweight mounting bolt

45

6

65

3920

400

2890

Front pin lock bolt (Loader) A Front pin lock bolt B Bucket pin lock bolt C Bucket pin lock bolt D Bucket pin lock bolt

20 20 16 12

14 4 18 6

30 ∗17 24 19

390 540 265 88

40 55 27 9

290 400 195 65

Front pin lock bolt (Backhoe) A Front pin lock bolt B Stopper bolt C Gap adjusting bolt

20 20 22

12 12 4

30 30 32

390 390 540

40 40 55

290 290 400

Side cutter mounting bolt

33

12

50

2550

260

1880

NOTE: ∗ Hexagonal socket wrench

W1-2-1


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 the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components.

Hexagon T Bolt

Hexagon H Bolt

SA-040

Hexagon M Bolt

Socket Bolt

W105-01-01-007

Specified Tightening Torque Chart Hexagon T Bolt, Socket bolt Bolt Wrench Wrench Dia. Size N⋅m kgf⋅m lbf⋅ft Size M 8 13 6 29.5 3 22 M 10 17 8 64 6.5 47 M 12 19 10 108 11 80 M 14 22 12 175 18 130 M 16 24 14 265 27 195 M 18 27 14 390 40 290 M 20 30 17 540 55 400 M 22 32 17 740 75 540 M 24 36 19 930 95 690 M 27 41 19 1370 140 1010 M 30 46 22 1910 195 1410 M 33 50 24 2550 260 1880 M 36 55 27 3140 320 2310

H Bolt N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-2

kgf⋅m 2 5 9 14 21 30 40 55 70 105 145 195 245

M Bolt lbf⋅ft 14.5 36 65 101 152 220 290 400 505 760 1050 1410 1770

N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

kgf⋅m 1 2 3.5 5.5 8 12 17 22 28 40 55 75 95

lbf⋅ft 7.2 14.5 25.5 40 58 87 123 159 205 290 400 540 690


GENERAL INFORMATION / Tightening IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. (2) Torque tolerance is Âą10 %. (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 the 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 alternately

1,4

Tighten from center and diagonally

Tighten diagonally

1 6

3

4

5 2

12

9

4

1

6

7

14

13

8

5

2

3

10

11

2,3

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 Orings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place. (3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Handtighten the bolts to hold the 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 tighten 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 Lockings

• 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

RIGHT

RIGHT

WRONG

Bend along edge sharply W105-01-01-009

RIGHT

RIGHT

WRONG

IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction. RIGHT

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-4


GENERAL INFORMATION / Tightening PIPING JOINT

1

4

3

5

2

Pipe Thread Connection / Union Joint Tightening Torque Specifications Union Joint Joint Body

Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

M202-07-051

30° or 37°

IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

30° or 37°

Male Union Joint

W105-01-01-017

(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.

Type 30° Male Union Joint

37° Female Union Joint

Wrench Size Union Nut Joint Body 19 19 22 22 27 27 36 36 41 41 50 50 60 60 70 70 17 19 19 22 22 27 30, 32 36 36 41 46 50

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

W1-2-5

Female Union Joint

Tightening Torque N⋅m (kgf⋅m) Ibf⋅ft 43 59 (6) 72 98 (10) 87 118 (12) 134 235 (24) 215 295 (30) 360 490 (50) 490 670 (68) 720 980 (100) 32.5 44 (4.5) 43 59 (6) 87 118 (12) 134 235 (24) 215 295 (30) 360 490 (50)


GENERAL INFORMATION / Tightening O-ring Seal Joint

7

6

9

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 union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with Oring (6) displaced will damage Oring (6), resulting in oil leakage. (3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage. (4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

W1-2-6

8

Joint Body

10

M104-07-033

Wrench Size Union Nut Joint Body 19 22 27 36 41 50

17 19 22 30, 32 36 46

Tightening Torque N⋅m (kgf⋅m) Ibf⋅ft 59(6) 98(10) 118(12) 235(24) 295(30) 490(50)

43 72 87 134 215 360


GENERAL INFORMATION / Tightening Screwed-In Connection

PT

PF

IMPORTANT: Many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

30°

Male Tapered Thread

Male Straight Thread

W105-01-01-018

Male Tapered Thread Wrench Tightening Torque Joint Body N⋅m (kgf⋅m) Ibf⋅ft 43 59 (6) 17, 19 72 98 (10) 19, 22 87 118 (12) 27, 22 134 235 (24) 36, 32 215 295 (30) 41 360 490 (50) 50 490 670 (68) 60 720 980 (100) 70

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

Internal Thread

• Application Procedure External Thread

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

Clearance

W105-01-01-019

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. See below for correct tightening torque of each type of low-pressure-hose clamp.

M114-07-041

T-Bolt Type

Worm Gear Type

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 )

M114-07-042

W1-2-7

M114-07-043


GENERAL INFORMATION / Tightening Connecting Hose WRONG CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) 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 that hoses do not come into contact with moving parts or sharp objects.

RIGHT

W105-01-01-011

WRONG

RIGHT Rubbing Against Each Other

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing

W105-01-01-013

WRONG

RIGHT

Rubbing Clamp

W105-01-01-014

W1-2-8


SECTION 2

UPPERSTRUCTURE —CONTENTS— Group 1 Cab

Group 5 Swing Device

Remove and Install Cab ......................... W2-1-1

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

Dimensions of the Cab Glass ................. W2-1-6

Disassemble Swing Device..................... W2-5-4 Assemble Swing Device ......................... W2-5-8

Group 2 Counterweight

Disassemble Swing Motor .................... W2-5-14

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

Assemble Swing Motor ......................... W2-5-18 Disassemble and Assemble

Group 3 Pump Device

Swing Parking Brake Release Valve ... W2-5-22

Remove and Install Pump Device ........... W2-3-1

Maintenance Standard.......................... W2-5-24

Disassemble Main Pump ........................ W2-3-2 Assemble Main Pump............................. W2-3-4 Maintenance Standard ........................... W2-3-6 Disassemble Regulator .......................... W2-3-8 Assemble Regulator ............................. W2-3-12 Disassemble and Assemble Fuel Cooler

Group 6 Pilot Valve Remove and Install Right Pilot Valve ..................................... W2-6-1 Remove and Install Left Pilot Valve........................................ W2-6-5

Fan Motor Drive Pump and

Remove and Install

Transmission Lubricating Pump .......... W2-3-18 Disassemble and Assemble

Travel Pilot Valve .................................... W2-6-9 Disassemble Right and

Pilot Pump .......................................... W2-3-20

Left Pilot Valve...................................... W2-6-12 Assemble Right and

Group 4 Control Valve

Left Pilot Valve...................................... W2-6-14

Remove and Install Control Valve ........... W2-4-1

Disassemble Travel Pilot Valve............... W2-6-18

Disassemble Main Control Valve 1 ......... W2-4-4

Assemble Travel Pilot Valve ................... W2-6-20

Assemble Main Control Valve 1 .............. W2-4-6

Disassemble Bucket Open-Close

Disassemble Main Control Valve 2 ......... W2-4-8 Assemble Main Control Valve 2 ............ W2-4-10 Disassemble Main Control Valve 3 ....... W2-4-12

Pilot Valve (For Loading Shovel) ........... W2-6-24 Assemble Bucket Open-Close Pilot Valve (For Loading Shovel) ........... W2-6-26

Assemble Main Control Valve 3 ............ W2-4-14 Disassemble Main Control Valve 4 ....... W2-4-16 Assemble Main Control Valve 4 ............ W2-4-18

Group 7 Pilot Shut-Off Valve Remove and Install

Disassemble Swing Control Valve 1...... W2-4-20

Pilot Shut-off Valve ................................. W2-7-1

Assemble Swing Control Valve 1 .......... W2-4-22

Disassemble Pilot Shut-off Valve .............. W2-7-2

Disassemble Swing Control Valve 2...... W2-4-24

Assemble Pilot Shut-off Valve................... W2-7-4

Assemble Swing Control Valve 2 .......... W2-4-26

142W-2-1


Group 8 Shockless Valve Remove and Install Shockless Valve ........ W2-8-1 Disassemble and Assemble Shockless Valve ..................................... W2-8-2

Group 9 Solenoid Valve Unit ⋅ Solenoid Valve ⋅ EHC Valve Remove and Install Solenoid Valve Unit ⋅ Solenoid Valve ⋅ EHC Valve .................... W2-9-1 Disassemble and Assemble Solenoid Valve Unit................................. W2-9-3 Disassemble and Assemble Solenoid Valve........................................ W2-9-4 Disassemble and Assemble EHC Valve .............................................. W2-9-5

Group 10 Fuel Cooler Fan Motor Remove and Install Fuel Cooler Fan Motor .......................... W2-10-1 Disassemble and Assemble Fuel Cooler Fan Motor .......................... W2-10-3

Group 11 Air Conditioner Work after Component Replacement...... W2-11-1 Add Compressor Oil ............................... W2-11-1 Charge Air Conditioner with Refrigerant . W2-11-2

142W-2-2


UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Removal

1

1. Remove mounting bolts (1) from cover (2) located at the front of the cab floor. Remove cover (2). Disconnect washer hose (3) located under the cab floor. 2

: 10 mm

T142-02-05-033

3 Disconnect

T142-02-05-024

2. Remove caps (5) from duct-cover-mounting screws (4). Duct cover (6) is located on the lower part of the monitor console, as illustrated. Loosen screws (4) to remove duct cover (6). NOTE: No cap is provided on the one screw (4) located on the lower end of the duct cover. 6 4, 5 T142-02-05-025

3. Accessing from the cover opening, loosen bolts (8) located on rear duct (7). Push middle duct (9) into rear duct (7) to pull out middle duct (9) from front duct (10).

10

9

8

7

: 10 mm

T142-02-05-026

W2-1-1


UPPERSTRUCTURE / Cab 4. Remove bolts (13) located on the rear part of the cab inside. Remove bolt (14) from the inside of each rear box (11) and (12) to remove rear boxes (11) and (12). Loosen clamp (15) to disconnect hose (16) end from rear box (11).

14 12 13 14

: 13 mm 13

15

11

16 T142-02-05-027

5. Remove bolts (18) from fresh air duct (17), located at the rear of the cab as illustrated, to remove fresh air duct (17).

18 Cab Inside

Cab Outside

17

: 13

mm

6. Remove bolt (19) from the top of SMJ connector (20), located at the right rear side of the cab. Disconnect SMJ connector (20) to disconnect the cable.

T142-02-05-028

19 20

: 10 mm

T142-02-05-029

7. Disconnect radio-antenna connector (21) located under the left console.

21

T142-02-05-030

W2-1-2


UPPERSTRUCTURE / Cab CAUTION: Cab weight: 620 kg (1370 lb) 8. Attach wire ropes to the cab.

T142-02-05-031

9. Remove bolts (22) and (23). Lift and remove the cab using a crane. 23

: 24 mm, 17 mm 22

T142-02-05-032

Installation CAUTION: Cab weight: 620 kg (1370 lb) 1. Attach wire ropes to the cab. Lift and install the cab into position on the base machine using a crane.

T142-02-05-031

2. Tighten bolts (22) and (23) with washers (24) to secure the cab on the cab bed. 23

: 24 mm : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

24 22

: 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

T142-02-05-032

W2-1-3


UPPERSTRUCTURE / Cab 3. Connect radio-antenna connector (21) located under the left console.

21

4. Connect SMJ connector (20), located at the right rear side of the cab, using bolt (19).

T142-02-05-030

19

: 10 mm : 12 to 17.5 N⋅m (1.2 to 1.8 kgf⋅m, 8.7 to 13 lbf⋅ft)

20

T142-02-05-029

5. Install fresh air duct (17) on the rear wall of the cab using bolts (18).

18

: 13 mm : 9.8 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)

Cab Inside

Cab Outside

17

T142-02-05-028

6. Connect hose (16) end to rear box (11) using clamp (15). Install rear boxes (11) and (12) using bolts (13) and (14).

14 12 13

: 13 mm : 9.8 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)

14 13

11

15 16 T142-02-05-027

W2-1-4


UPPERSTRUCTURE / Cab 7. Pull out middle duct (9) into front duct (10). Secure middle duct (9) to rear duct (7) using bolts (8).

10

9

8

7

: 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.1 to 2.9 lbf⋅ft)

T142-02-05-026

8. Install duct cover (6) onto the monitor console using screws (4). Attach cap (5) onto each screw (4), except on the one located on the lower part of the cover. NOTE: No cap is provided for the one screw (4) located on the lower part of the cover.

6 4, 5 T142-02-05-025

3

9. Connect washer hose (3) located under the cab floor. Install cover (2) at the front of the cab floor using bolts (1).

Disconnect

: 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.1 to 2.9 lbf⋅ft)

T142-02-05-024

1

2

T142-02-05-033

W2-1-5


UPPERSTRUCTURE / Cab DIMENSION OF THE CAB GLASS Unit : mm NOTE: 1 mm=0.03937 in Material: JIS-R3211 ANSI-AS2 ECE-ANNEX5 or equivalent Chamfer fringe corners Thickness: 8.8 mm

Chamfer fringe corners Thickness: 5 mm

Round windowpane edge all around Thickness: 5 mm

Round windowpane edge all around Thickness: 5 mm

Chamfer fringe corners Thickness: 5 mm

Round windowpane edge all around Thickness: 5 mm

Chamfer fringe corners Thickness: 5 mm Chamfer fringe corners Thickness: 5 mm

Chamfer fringe corners Thickness: 5 mm

T142-02-05-034

W2-1-6


UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Approximate counterweight weight: 16500 kg (36400 lb) 2

1. Install lifting accessories on the top of the counterweight. Connect the counterweight to a crane using a wire rope. Pull the wire rope taut using a crane. Loosen bolt (1) to remove cover (2).

1

: 19 mm T142-02-05-019

CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit by the reaction bar.

5 6

2. Loosen bolts (3) and (4) using a power wrench. Remove bolts (3) and (4), nut (5), plate (6) and washer (7).

7 7

Power Wrench

3

Wrench size: 65 mm 7 4

T142-02-05-020

7

6

7

5

3

7

T142-02-05-021

4

3. Lift and remove the counterweight using the crane.

T142-02-05-022

W2-2-1


UPPERSTRUCTURE / Counterweight Installation CAUTION: Approximate counterweight weight : 16500 kg (36400 lb) 1. Install lifting accessories on the top of the counterweight. Connect the counterweight to a crane using a wire rope. Pull the wire rope taut. ȀȀ T142-02-05-022

CAUTION: Never counterweight.

get

under

the

lifted

5 6 7

2. Lift and place the counterweight on the frame.

7

Power Wrench

3 7 4

CAUTION: Watch out the power-wrench reaction bar movement. Take care not to be hit by the reaction bar.

T142-02-05-020

Outside Outside

IMPORTANT: Apply a film of lubricant to bolts (3) and (4) before installing them. Be sure to position plate (6) so that its chamfered side faces the outside when installing it. 3. Install bolts (3) and (4), nut (5), plate (6) and washer (7). Tighten bolts (3) and (4) using a power wrench. Wrench size: 65 mm : 3920 N⋅m (400 kgf⋅m, 2890 lbf⋅ft)

6 Chamfered T142-02-05-023

7

6

7

5

3

T142-02-05-021

7

4

4. Remove lifting accessories and wire rope. Install cover (2) using bolt (1) and washer (10). 2

: 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

1, 10

T142-02-05-019

W2-2-2


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Hitachi ex1100 3 excavator service repair manual  
Hitachi ex1100 3 excavator service repair manual  
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