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ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
2
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C 1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688 SA-688
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
SA-434
006-E01A-0434
INSPECT MACHINE
007-E01A-0435 SA-435
SA-3
SAFETY
SAFETY OPERATORS STATION
SA-4
SAFETY
USE HANDHOLDS AND STEPS
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.
008-E01A-0439
again.
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT
012-E01B-0444
JUMP STARTING
013-E01A-0032
SA-379
014-E01B-0379
SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
018-E01A-0481
SA-481
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-388
SA-441
SA-589
019-E01C-0492
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
Select level ground when possible to park machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode switch off. SA-391
020-E02A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
029-E01A-0381
SA-12
SAFETY
OBJECT HANDLING
032-E01A-0014
031-E01A-0432
SA-432
SA-13
SAFETY
PARK MACHINE SAFELY
To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch and H/P mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK SA-390
position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E08B-0390
034-E01A-0496
SA-019
SA-14
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-15
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from power-driven
parts.
SA-16
SAFETY
Be sure to use incombustible detergent oils to clean
parts. Never use flammable materials such as gaso-
line when cleaning the machine and/or parts.
Illuminate your work area adequately but safety.
Use a portable safety light for working inside or under
the machine
Make sure that the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ig-
nite spilled fuel or oil.
SA-037
500-E02B-0497
SA-287
S501-E01A-0287
SA-17
SAFETY
STAY CLEAR OF MOVING PARTS
502-E01A-0026 SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034 SA-034
S522-E01A-0040
SA-040
SA-19
SAFETY
PREVENT BURNS
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
Wait for the oil and components to cool before starting
any maintenance or inspection work.
505-E01B-0498
SA-019
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.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
SA-044
507-E03A-0499
SA-21
SAFETY
PREVENT FIRES
Clean up Flammables:
Spilled fuel and oil, air conditioning refrigerant,
windshield washer and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
SA-22
SAFETY
Check Heat Shields:
Damaged or missing heat shields may lead to fires.
508-E02A-0393
518-E02A-0393 SS-1510
509-E01A-0016
SA-016
SA-23
SAFETY
PRECAUTIONS FOR WELDING AND REPAIR
WORK WITH GRINDER
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
SA-029
Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least
15 minutes before welding or heating.
511-E01A-0029
SA-25
SAFETY
PREVENT BATTERY EXPLOSIONS
512-E01B-0032
SA-405
513-E01A-0405
SA-26
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
515-E01A-0309
516-E01A-0226
SA-27
SAFETY
BEFORE RETURNING THE MACHINE TO THE
CUSTOMER
SA-4.35
SA-28
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
WORKSHOP MANUAL Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless 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 (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
SECTION 2 SYSTEM Group 3 Control Valve
Group 1 Control System Group 4 Pilot Valve
Group 2 Hydraulic System Group 5 Travel Device
Group 3 Electrical System Group 6 Others(Upperstructure)
Group 7 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Component Layout
Group 2 Engine Test Group 3 Troubleshooting A
Group 3 Excavator Test Group 4 Troubleshooting B
Group 4 Hydraulic Component Test Group 5 Troubleshooting C
Group 5 Standard Group 6 Electrical System Inspection
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology........ W1-1-7
183W-1-1
(Blank)
183W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Thoroughly wash the machine before bringing it into To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place on a work bench.
damage to machine components, as well as Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help If a part or component cannot be removed after
avoid incorrect disassembling of components as well removing its securing nuts and bolts, do not
as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. Orderly arrange disassembled parts. Mark and
tag them as necessary.
The machine model, machine serial number, and Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). Inspect the contact or sliding surfaces of
Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
Capacities and condition of lubricants. or other damage.
Loose or damaged parts. Measure and record the degree of wear and
clearances.
Prepare and Clean Tools and Disassembly Area
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling Bleeding Air from Hydraulic System
Be sure to clean all parts and inspect them for any When hydraulic oil is drained, the suction filter or the
damage. If any damage is found, repair or replace suction lines are replaced, or the removal and instal-
part. lation of the pump, swing motor, travel motor or cylin-
Dirt or debris on the contact or sliding surfaces der is done, bleed air from the hydraulic system in the
may shorten the service life of the machine. Take following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
If an anti-corrosive agent has been used on a new
may result.
part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
Utilize matching marks when assembling. trapped in the cylinder tube, damage
Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the plug.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic Circuit
W183-04-02-002
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
uneven wear.
b b
a=b a b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
Allowable Limit
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
W1-2-1
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
W162-01-01-001
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubri-
cant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop suf-
ficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Spilt Flange
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
W105-01-01-009
ening, not while loosening.
RIGHT RIGHT WRONG
Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 7 6 9
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
W1-2-10
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Disassemble Main Control Valve 2
Remove and Install Cab ...................... W2-1-1 (5-Spool Section) ............................. W2-4-16
Dimensions of the Cab Glass ............ W2-1-15 Assemble Main Control Valve 2
(5-Spool Section) ............................. W2-4-18
Group 2 Counterweight Disassemble Main Control Valve 1
Remove and Install Counterweight ...... W2-2-1 (4-Spool Section) ............................. W2-4-20
Assemble Main Control Valve 1
Group 3 Pump Device (4-Spool Section) ............................. W2-4-28
Remove and Install Pump Device ........ W2-3-1 Disassemble Main Control Valve 2
Disassemble Pump Transmission........ W2-3-4 (4-Spool Section) ............................. W2-4-34
Assemble Pump Transmission ............ W2-3-6 Assemble Main Control Valve 2
Disassemble Main Pump ..................... W2-3-8 (4-Spool Section) ............................. W2-4-36
Assemble Main Pump........................ W2-3-12 Disassemble Manifold ....................... W2-4-38
Maintenance Standard ...................... W2-3-14 Assemble Manifold ............................ W2-4-40
Disassemble Regulator(Main Pump) . W2-3-16 Disassemble Swing Control Valve 1... W2-4-42
Assemble Regulator(Main Pump) ...... W2-3-20 Assemble Swing Control Valve 1 ....... W2-4-48
Disassemble Pump of Disassemble Swing Control Valve 2... W2-4-52
Oil Cooler Fan Motor ....................... W2-3-26 Assemble Swing Control Valve 2 ....... W2-4-54
Assemble Pump of
Oil Cooler Fan Motor ....................... W2-3-30 Group 5 Swing Device
Maintenance Standard ...................... W2-3-32 Remove and Install Swing Device........ W2-5-1
Disassemble Regulator(Pump for Disassemble Swing Reduction Gear .... W2-5-6
Driving Oil Cooler Fan Motor) .......... W2-3-34 Assemble Swing Reduction Gear....... W2-5-12
Assemble Regulator(Pump for Disassemble Swing Motor ................. W2-5-16
Driving Oil Cooler Fan Motor) .......... W2-3-38 Assemble Swing Motor ...................... W2-5-20
Configuration of Pilot Pump ............... W2-3-44 Disassemble and Assemble Swing
Configuration of Pump for Parking Brake Releasing Valve ........ W2-5-24
Lubricating Pump Transmission ....... W2-3-46 Maintenance Standard....................... W2-5-26
183W-2-1
Group 6 Pilot Valve Group 11 Oil Cooler Fan Motor
Remove and Install Right Pilot Valve ... W2-6-1 Remove and Install Oil Cooler
Remove and Install Left Pilot Valve ..... W2-6-5 Fan Motor ........................................ W2-11-1
Remove and Install Travel Pilot Valve. Disassemble Oil Cooler Fan Motor .... W2-11-4
Remove and Install Bucket Pilot Assemble Oil Cooler Fan Motor ......... W2-11-6
Valve(for Loading Shovel Only) .......... W2-6-9
Disassemble Front Pilot Valve ........... W2-6-14
Assemble Front Pilot Valve................ W2-6-18
Disassemble Travel Pilot Valve.......... W2-6-22
Assemble Travel Pilot Valve .............. W2-6-26
Disassemble Pilot Valve for
Bucket Opening / Closing ................ W2-6-32
Assemble Pilot Valve for
Bucket Opening / Closing ................ W2-6-34
183W-2-2
UPPERSTRUCTURE / Cab
Removal
W183-02-01-040
8 6
3. Disconnect cigarette lighter connector (4), buzzer
cancel switch connector (5) and troubleshooting 9
switch connector (6), from inside of rear box (7).
Then remove rear box (7).
W183-02-01-002
W2-1-1
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