Hitachi zaxis zx 17u 2 excavator service repair manual by 1631278

INTRODUCTION

ADDITIONAL REFERENCES Please refer to the other materials (operator s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

MANUAL COMPOSITION This manual consists the Technical Manual and the Workshop Manual. 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 Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

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 3 m kg N N Nm Nm

Into in ft US gal US qt 3 yd lb kgf lbf kgf m lbf ft

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 -1 min 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. SA-1223

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

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 authorized 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 authorized 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 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 OPERATOR S SPACE Always keep inside the operator s space 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 operator s space. 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. Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. 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 operator s space. Do not leave cigarette lighters 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

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR S SEAT Before rising from the operator s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.

Before leaving the machine, close all windows, doors, and access covers and lock them up.

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 PRECAUTIONS FOR OPERATIONS WARNING: Thoroughly make certain safety at the work site before starting operations. Especially always observe the following points. Be sure to install the overhead cab guard before operating the machine in areas where the possibility of falling stones or debris exists.

If operation on soft ground is required, sufficiently reinforce the ground beforehand.

Be sure to wear close fitting clothing and required safety items, such as a hard hat, when operating the machine.

Keep all bystanders and unnecessary objects out of and away from the machine working areas. Always beware of the surroundings while operating the machine. Take care not to allow the rear part of the upperstructure to come in contact with objects when swinging the machine in a small area.

When loading a dump truck, bring the bucket from the rear side of the dump truck to avoid moving the bucket over the dump truck cab or over any co-workers.

SA-8

M586-12-012

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.

SA-1293

 Never allow bystanders to enter the working area such as swing radius or traveling range.  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.

Make sure the work site ground has sufficient strength to firmly support the machine. When working close to an excavation or on road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front, so that the machine can more easily evacuate if the cliff face collapses.

If working at the bottom of a cliff or on a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work in that area. M586-05-021

Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong enough and firm to easily support the machine.

Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. Operate the machine slowly to ensure safe operation.

SA-9

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-10

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 driving the machine, always confirm that the travel pedals/levers direction corresponds to the direction you wish to drive.

 Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

SA-1295

Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. Never attempt to ascend or descend 25 degrees or steeper slopes.

Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (8 to 12 in) (A) above the ground.  If machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

A SA-1296

 Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.

SA-441

SA-442

SA-11

SAFETY Traveling down a slope in the fast mode requires a longer time to stop the machine. When traveling down a slope, placing engine control lever (1) in the TURTLE position.

Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.

M1MW-04-002

If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral. Then, restart the engine.

Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.

Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.

Travel Motor

M104-05-008

Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.

Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.

When the machine is equipped with steel shoes, cover the road surface with wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer.

Do not make contact with electric wires or bridges.

SA-673

When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.

When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine.

Avoid operations that may damage the track and undercarriage components.

During freezing weather, always clean snow and ice from track shoes before driving the machine on snowy and/or frozen roads, or loading and unloading the machine for transportation, to prevent the machine from slipping.

SA-12

M586-05-002

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 SA-19 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-13

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

SA-383

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

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-14

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-15

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-16

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-17

SA-1305

SAFETY PRECAUTIONS FOR LIGHTENING The machine is vulnerable to lighting strikes. In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-1805

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.

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.

Keep bystanders away from the working area before striking any object. SA-432

SA-18

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. 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-19

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 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. Slowly drive the machine. 6. 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. 7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 8. Wedge the front and rear of tracks. Securely fasten the machine to the trailer bed with chain or cables. 9. Do not operate any levers besides the travel levers when driving up or down the ramp. 10. Prevent possible injury from machine tipping while the upperstructure is rotating. 11. Keep the arm tucked under and rotate the upperstructure slowly for best stability.

Refer to "transporting" chapter in the operator s manual for details

SA-20

SA-1307

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-21

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

SA-22

SAFETY 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

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. SA-344

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

SA-23

SAFETY 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

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-24

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-25

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-26

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.

Do not store flammable fluid near open flames. Do not burn or crush a pressurerized container. Do not store oily cloths. They are liable to catch fire. Do not 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-27

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. SA-393

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

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

BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

Keep bystanders out of the work site during operation. SA-029

Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-28

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-29

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 SA-029

welding or heating.

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-30

SA-032

SAFETY 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 authorized dealer for MSDS.

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-31

SA-226

SAFETY (Blank)

SA-32

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank

WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE Group 1 Canopy and Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Solenoid Valve

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 Hydraulic System Group 2 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others (Upperstructure) Group 7 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 B Group 3 Troubleshooting C Group 4 Electrical System Inspection

SECTION 1

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

Group 2 Tightening Tightening Torque .................................... W1-2-1 Tightening Bolts and Nuts........................ W1-2-2 Piping Joint.............................................. W1-2-5 Periodic Replacement Parts .................. W1-2-10

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

Group 4 Bleeding Air From Hydraulic Oil Tank Bleeding Air from Hydraulic Oil Tank (Canopy Spec) ....................................... W1-4-1 Bleeding Air from Hydraulic Oil Tank (Cab Spec) ............................................ W1-4-2

1MSW-1-1

(Blank)

1MSW-1-2

GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Preparation before Disassembling Clean the Machine 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 and result in damage to machine components, as well as decreased efficiency in service work. Inspect the Machine Thoroughly understand all disassembling / assembling procedures beforehand in order to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below in order to prevent problems from occurring in the future. The machine model, machine serial number and hour meter. Symptoms, failed parts and causes. Contamination and clogging of filters, quality and quantity of lubricants and leakage of oil, air or water. Damage and loosening of various parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. In addition, clean the tools and area. When disassembling and assembling Disassemble In order to prevent dirt from entering, cap or plug the removed pipes. Before disassembling, clean the exterior of the machine and place it on a workbench. Before disassembling, drain gear oil from the reduction gear. Provide appropriate containers for draining fluids. Put the matching marks for easier reassembling. Use the specified special tools when instructed.

W1-1-1

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) and take the appropriate measures to remove it. Orderly arrange disassembled parts. Put the mark and tag as necessary. Store the 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. When assembling Clean all parts and inspect them for any damage. If any damage is found, repair or replace the part. Dirt or debris on the contact or sliding surfaces may shorten the service life of machine. Do not contaminate any contact or sliding surfaces. Apply hydraulic oil or gear oil onto the inner parts when assembling. Especially apply clean hydraulic oil or gear oil onto the sliding part in order not to stick. Replace O-rings, backup rings, oil seals and floating seals with new ones once they are disassembled. Apply a film of grease before installing. Clean and dry the liquid-gasket-applied surfaces. If an anti-corrosive agent has been used on a new part, thoroughly clean the part to remove the agent. Align the matching marks when assembling. Use the designated tools when assembling the bearings, bushings and oil seals. After assembling is complete, count the number of tools in order not to leave the tools in the assembled machine.

GENERAL / 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 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 when air is trapped in the hydraulic pump and there is no hydraulic oil in it, the pump may be damaged. If the hydraulic motor is operated when air is trapped in it and there is no hydraulic oil in it, the motor may be damaged. If the cylinder is operated abruptly when air is trapped in the cylinder tube and there is no hydraulic oil in it, the seal may be damaged or the cylinder may be stuck. Be sure to bleed air before starting the engine. Bleeding Air from Hydraulic Pump Remove the air bleeding plug from top of the pump. Then, fill the pump with hydraulic oil. After the pump is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. Slightly loosen the plug and bleed air from the pump until hydraulic oil oozes out. After bleeding all air, securely tighten the plug. Bleeding Air from Travel Motor / Swing Motor Remove the air bleeding plug (upper) from travel motor and swing motor. Then, fill the motor case with hydraulic oil.

W1-1-2

GENERAL / Precautions for Disassembling and Assembling Bleeding Air from Hydraulic Circuit 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. (Do not fully stroke the cylinders during initial operation stage.) As the pilot circuit has an air bleed device, air trapped in the pilot circuit will be bled while performing the above operation for approx. 5 minutes. Reposition the front attachment in order to check hydraulic oil level. After stopping the engine, check hydraulic oil level. Replenish oil as necessary.

W1-1-3

M1M7-05-024

GENERAL / Precautions for Disassembling and Assembling Precautions for Floating Seal A

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures. (1) Keep the seal rings together as a matched set. Apply oil onto sliding surface (C) on seal ring (A). Insert a piece of cardboard to protect surfaces. (2) Check sliding surface (C) on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. Check the step part. (3) Check O-ring (B) for tears, breaks, deformation of hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. (1) Clean the seal mounting bores. Use a wire brush in order to remove mud, rust or dirt from the mounting bores. (After cleaning, thoroughly dry the parts.) (2) Clean the mounting bores of seal ring (A) or O-ring (B). Check the bore surface for scuffing or scoring. (Check by touching the seal surface by fingers). (3) After installing to seal ring (A), check that O-ring (B) is not twisted and deformed. (4) Check that seal ring sliding surface (C) is parallel with seal mounting surface (D) and O-ring (B) by measuring the distance (A) and (D) at point (a) and (b) as illustrated. If these distance differ, correct the O-ring seating.

W105-03-05-019

Correct

C O-Ring Twist Incorrect O-Ring Bend

W105-03-05-020

D Correct

Incorrect a

b a b

W1-1-4

b a b

W110-03-05-004

GENERAL / Precautions for Disassembling and Assembling Precautions for Nylon Sling 1. Follow the precautions below in order to use the nylon slings safely. Attach protectors (soft material) on the corners of load so that the nylon sling does not directly contact the corners. Using the protectors will prevent the nylon sling from being damaged and the lifted load from slipping. Lower 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. As the load may slip, take care not to allow the sling to become wet. When required to use more than one sling, use slings with the same width and length in order to keep the lifted load balanced. When lifting a load by using an eyehole (refer to the right illustration), be sure to eliminate any gaps between the sling and load. 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, do not damage the nylon slings. Avoid contact with protrusions. Avoid dragging the nylon slings on the ground, throwing the nylon slings or pushing the nylon slings with a metal object. When using with other types of slings (wire rope) or accessories (shackle) together, protect the joint so that the nylon sling is not damaged. Store the nylon slings indoors so they may not deteriorate with heat, sun light or chemicals.

Correct Eyebolt Lifting Method

W102-04-02-016

Incorrect Eyebolt Lifting Method

W105-04-01-008

Bent Sling W162-01-01-009

W1-1-5

GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted by using a damaged nylon sling, serious personal injury may result. Visually check the nylon sling for any damage before using.

Damaged Appearance

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If an corresponding damage is found, cut and discard the nylon sling. Even if no damage is found, do not use the nylon slings older than 7 years.

Broken Sewing Thread

W162-01-01-002

Scuffing

W162-01-01-003

Fuzz Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Separation of Belt W162-01-01-006

Scuffing

W162-01-01-007

Fuzz 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 tolerance will be indicated as necessary.

Allowable Limit 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 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 / Tightening TIGHTENING TORQUE Item Descriptions 1. Engine cushion rubber mounting bolt 2. Engine bracket mounting bolt (front) 3. Hydraulic oil tank mounting bolt

5. Pump mounting bolt 6. Pump cover mounting bolt Control valve mounting bolt 7. Control valve mounting bolt 8. Swing device mounting bolt 9. Battery mounting nut 10. Canopy mounting bolt 11. Cab mounting bolt

13. 14. 15. 16.

Q'ty

12 10 12 7/16-20UNF

4 8 4

9/16-18UNF

Union joint for hydraulic hoses Metal joint and piping

12. Swing bearing mounting bolt

Bolt Dia.

Upperstructure Track

Travel device mounting bolt Sprocket mounting bolt Iron-crawler guide mounting bolt Lower roller mounting bolt

17. Covers mounting bolt 18. Counterweight mounting bolt

19. Front pin retaining bolt

3/4-16UNF 1-1/16-12UNF 12 10 10 10 12 6 10 12 12 16 10 10 10 10 10 14 6 8 10 20 8 10 12 14 16

NOTE: 1: Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (Example: white zinc B dissolved into Spindle oil) 2: Remove rust, dirt and dust before installing fasteners.

W1-2-1

2 8 4 4 4 4 3 4 4 4 16 18 16 18 8 12

Wrench Size 19 17 19 17 19 22 27 36 19 17 17 17 19 10 17 19 19 24 17 17 8 (Socket) 8 (Socket) 17 22 10 13 17 30 13 17 19 22 24

Nm 90 50 90 25 30 40 95 180 90 50 50 50 90 5 50 90 90 210 50 50 65 65 50 180 5 10 50 400 20 50 90 140 210

Torque (kgf m) (lbf ft) (9) (65) (5) (36) (9) (65) (2.5) (18) (3) (22) (4) (29) (9.5) (69) (18) (129) (9) (65) (5) (36) (5) (36) (5) (36) (9) (65) (0.5) (3.5) (5) (36) (9) (65) (9) (65) (21) (152) (5) (36) (5) (36) (6.5) (47) (6.5) (47) (5) (36) (18) (130) (0.5) (3.5) (1) (7) (5) (36) (41) (297) (2) (14) (5) (36) (9) (65) (14) (101) (21) (152)

GENERAL / Tightening TIGHTENING BOLTS AND NUTS 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 injure.

SA-040

Bolt Types Tighten the nuts or bolts correctly to the torque specifications.

As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components.

Specified Tightening Torque Chart

Bolt Dia.

Wrench Size

Hexagon Wrench Size

M552-07-091

M552-07-092

M552-07-090

Socket Bolt Nm M6

(kgf m)

(lbf ft)

(kgf m)

(lbf ft)

Nm 3.3 to 4.2

(kgf m)

(lbf ft)

(0.3 to 0.4) (2.4 to 3.0)

(3.0)

(21.5)

(2.0)

(14.5)

(1.0)

(7.2)

M10

(6.5)

(47)

(5.0)

(36)

(2.0)

(14.5)

M12

110

(11)

(80)

(9.0)

(65)

(3.5)

(25.5)

M14

180

(18)

(130)

140

(14)

(101)

(5.5)

(40)

M16

270

(27)

(195)

210

(21)

(152)

(8.0)

(58)

M18

400

(40)

(290)

300

(30)

(215)

120

(12)

(87)

M20

550

(55)

(400)

400

(40)

(290)

170

(17)

(123)

M22

750

(75)

(540)

550

(55)

(400)

220

(22)

(159)

M24

950

(95)

(690)

700

(70)

(510)

280

(28)

(205)

M27

1400

(140)

(1010)

1050

(105)

(760)

400

(40)

(290)

M30

1950

(195)

(1410)

1450

(145)

(1050)

550

(55)

(400)

M33

2600

(260)

(1880)

1950

(195)

(1410)

750

(75)

(540)

M36

3200

(320)

(2310)

2450

(245)

(1770)

950

(95)

(690)

W1-2-2

GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (for example, spindle oil with white zinc B dissolved in it) 2. Torque tolerance is 10 %. 3. Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torques. 5. Clean the nut and bolt threads and remove dirt or corrosion before installing. Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower alternately

Tighten diagonally 1

1.4

Tighten from center diagonally 12

6 4

5 2

2.3 W105-01-01-003

W1-2-3

GENERAL / Tightening Precautions for Spilt Flange IMPORTANT: 1. Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring. 2. Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place. 3. While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring. 4. Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque. 5. Do not use air wrenches. Using an impact 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

Incorrect

W105-01-01-016

W105-01-01-008

Nut and Bolt Locking Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice. Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut. Always turn in the tightening direction. Do not reuse the split pins. Wire IMPORTANT: Attach wire to bolts in the bolt-tightening direction. Do not reuse the wire.

Correct

Incorrect

Do not bend it round

Bend along edge sharply

Correct

Bend along edge sharply

Correct

Incorrect

W105-01-01-009

Correct

Loosen

Incorrect

Tighten

W105-01-01-010

W1-2-4

GENERAL / Tightening PIPING JOINT IMPORTANT: The torques given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torques. 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 union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adaptor. Tighten union nut (3) to the 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.

Joint Body M202-07-051

37 30

Male Union Joint

Female Union Joint W105-01-01-017

Description 30

male

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, 29) 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, 29) 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 / Tightening Pipe joint Pipe connection (metal joint) (Union Nut Wrench Size: 17) Metal (3) of adaptor (1) and hose (2) seals pressure oil. Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.

Tightening Torque Use the specified tightening torque in the table below. Wrench Size (mm) 17 Nm 39 Tightening (kgf m) (4.0) Torque (lbf ft) (29)

M1M7-07-005

O-ring Seal Joint O-ring (6) is installed against the end face of adapter (7) and seals pressure oil. IMPORTANT: 1. Replace O-ring (6) with a new one when reinstalling. 2. Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may 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 O-ring groove (8).

Joint Body M104-07-033

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

Tightening Torque N m (kgf m, lbf ft) 29.5 (3.0,21.5) 69 (7.0,51) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 205 (21.0,151)

GENERAL / Tightening Quick Coupling 1. Coupling procedure Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you. Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction). 2. Separating procedure Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out. Cap the removed hoses using special plug. CAUTION: When disconnecting, do not damage joint surface. When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering. Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation. After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).

W1-2-7

2 M1M7-07-006

GENERAL / Tightening R

Screw-In Connection Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread is used except for measurement purpose.)

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, 22) 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 (32.5, 235) 195 (20, 144)

NOTE: Unit:N m (kgf m)

Seal Tape Application Seal tape is used in order to seal clearances between male and female threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

External Threadnal

Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the 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 Low-pressure-hose clamp tightening torque differs depending on the type of clamp. M114-07-041

T-Bolt Type Band Clamp: 4.4 N m (0.4 kgf m, 3.2 lbf ft) T-Bolt Type Band Clamp

Worm Gear Type Band Clamp

Worm Gear Type Band Clamp: 5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.4 to 5.1 lbf ft)

M114-07-042 M114-07-043

W1-2-8

GENERAL / Tightening Connecting Hose CAUTION: When replacing the hoses, 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.

Incorrect

Correct

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 the print marks on hoses when installing in order to prevent hose from being kinked.

W105-01-01-011

Incorrect Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture.

Correct

Rubbing Against Each Other

Take care so that the hoses do not come into contact with the moving parts or sharp objects.

W105-01-01-012

Incorrect Clamp

Correct Clamp

Rubbing Against Each Other W105-01-01-013

Incorrect

Correct

Rubbing Against Each Other Clamp W105-01-01-014

W1-2-9

GENERAL / Tightening PERIODIC REPLACEMENT PARTS In order to ensure safe operation, conduct periodic inspection of the machine. For this reason, replace these parts at the intervals shown in the table below. These parts may lead to serious disaster/fire hazards because of deterioration, fatigue, or weakening. It is very difficult to gauge the remnant life by sense of operation or visual inspection. Perform periodic inspection and maintenance and replace any defective parts if necessary.

Periodic Replacement Parts Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Engine

Engine rubber vibration insulator Pump coupling

Replacement Interval Every 2 years or 4000 hours whichever comes first Every 5 years or 3000 hours whichever comes first

Pump suction hose Pump delivery hose Base Machine Hydraulic System

Swing hose Auxiliary hose Oil cooler hose (C/V to oil cooler)

Every 2 years or 4000 hours whichever comes first

Boom cylinder line hose Arm cylinder line hose Front Attachment Bucket cylinder line hose Pilot hose Seat Belt

NOTE: Replace O-rings and the gaskets when replacing the hoses.

W1-2-10

Every 3 years

GENERAL / Painting PAINTING Surfaces to Be Painted Main surface of upper structure [Resin covers are excluded.] Swing post, swing cylinder Counterweight Canopy [including front panel], Cab Support, floor plate [Resin covers are excluded.]

Painting Color 3.4PB3.D/0.4 (SP-424) [Dark Gray]

Track, blade

3.4PB3.D/0.4 (SP-424) [Dark Gray]

Front, upperstructure cover part

0.5YR5.6/11.2(YR1-01) Yellow]

Control lever [travel, blade] Left stay

N-10 [N1.0] [Black]

[TAXI

Canopy spec Dark Gray Paint parts excluding seats and monitors

TAXI Yellow TAXI Yellow

Dark Gray Black Dark Gray [Spin-dyeing]

TAXI Yellow

TAXI Yellow Dark Gray

Dark Gray

Dark Gray [Including boom swing cylinder]

Black [Manufacture-paint parts]

Dark Gray [Including blade cylinder]

Dark Gray Dark Gray

Black

Dark Gray Dark Gray

Dark Gray

TAXI Yellow W1MS-01-03-001

W1-3-1

GENERAL / Painting Cab spec

Dark Gray (Manufacture-paint parts)

Dark Gray (Spin-dyeing)

Dark Gray

W1MS-01-03-002

W1-3-2

GENERAL / Bleeding Air from Hydraulic Oil Tank BLEEDING AIR FROM HYDRAULIC OIL TANK (CANOPY SPEC) CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Place the machine on a firm, level surface and lower the bucket to the ground. M1M7-05-024

2. Stop the engine. Loosen cap (1) on the air breather to release any remaining pressure from hydraulic oil tank (2).

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

M1MS-07-013

4. Connect a vacuum pump with the hole removed cap (1) to maintain negative pressure in the hydraulic oil tank (2). NOTE: Be sure to run the vacuum pump continuously while working.

Vacuum Pump

Hose

Adapter W1MP-01-04-001

W1-4-1

GENERAL / Bleeding Air from Hydraulic Oil Tank BLEEDING AIR FROM HYDRAULIC OIL TANK (CAB SPEC) CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

W1MS-01-04-001

Preparation 1. Place the machine on a firm, level surface and lower the bucket to the ground. Stop the engine.

2. Remove nut (5) (11 used) from cover (4). Remove cover (4) from cab (3). : 13 mm

5 4

3. Loosen cap (1) on the air breather to release any remaining pressure from hydraulic oil tank (2).

W1MS-02-01-002

4. Remove cap (1) of hydraulic oil tank (2). 1

5. Connect a vacuum pump with the hole removed cap (1) to maintain negative pressure in the hydraulic oil tank (2). NOTE: Be sure to run the vacuum pump continuously while working.

M1MS-07-013

Vacuum Pump

Hose

Adapter W1MP-01-04-001

W1-4-2

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SECTION 2

UPPERSTRUCTURE CONTENTS Group 1 Canopy and Cab

Group 6 Swing Device

Removal and Installation of

Canopy (2-Pillar).................................... W2-1-1 Removal and Installation of

Swing Device ......................................... W2-6-1 Disassembly of Swing Device .................. W2-6-4

Canopy (3-Pillar).................................... W2-1-2

Assembly of Swing Device..................... W2-6-10

Removal and Installation of Cab .............. W2-1-3 Dimensions of Cab Glass ........................ W2-1-7

Group 7 Pilot Valve Removal and Installation of Left

Group 2 Counterweight

Pilot Valve .............................................. W2-7-1

Removal and Installation of

Removal and Installation of Right

Counterweight

Pilot Valve .............................................. W2-7-3

(Canopy Spec. Machine) ....................... W2-2-1 Removal and Installaton of

Removal and Installation of Travel Pilot Valve .............................................. W2-7-9

Counterweight (Cab Spec. Machine) ..... W2-2-3

Removal and Installation of Blade Pilot Valve ............................................ W2-7-13

Group 3 Main Frame

Removal and Installation of Boom

Removal and Installation of

Swing Pilot Valve ................................. W2-7-17

Main Frame ........................................... W2-3-1

Disassembly of Left and Right Pilot Valves .......................................... W2-7-22

Group 4 Pump Device

Assembly of Left and Right

Removal and Installation of Pump Device ......................................... W2-4-1 Disassembly of Pump Device .................. W2-4-4 Assembly of Pump Device ....................... W2-4-6 Maintenance Standard............................. W2-4-8

Pilot Valves .......................................... W2-7-26 Disassembly of Travel Pilot Valve .......... W2-7-30 Assembly of Travel Pilot Valve ............... W2-7-34 Disassembly of Pilot Valves for Boom Swing, Blade, and Auxiliary........ W2-7-40 Assembly of Pilot Valves for

Group 5 Control Valve

Boom Swing, Blade, and Auxiliary........ W2-7-42

Removal and Installation of Control Valve ......................................... W2-5-1 Disassembly and Assembly of Control Valve ......................................... W2-5-8 Disassembly of Body ............................. W2-5-12 Assembly of Body .................................. W2-5-16 Disassembly of Spool ............................ W2-5-20 Assembly of Spool ................................. W2-5-26

Group 8 Solenoid Valve Removal and Installaiton of Solenoid Valve ....................................... W2-8-1 Disassembly of 2-Spool Solenoid Valve ....................................... W2-8-6 Assembly of 2-Spool Solenoid Valve ........ W2-8-8

Disassembly and Assembly of Check Valve......................................... W2-5-32

1MSW-2-1

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