INTRODUCTION
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni-
cal Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
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
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
• Information included in the Technical Manual
(Troubleshooting):
technical information needed for 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.
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.
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.
UNITS USED
• 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
Volume
Weight kg lb 2.205
To Convert
From
mm in 0.03937 Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
3
yd3 1.308
m
N kgf 0.10197 Force
N lbf 0.2248
N⋅m kgf⋅m 1.0197 Torque
N⋅m lbf⋅ft 0.7375
Into Multiply By
Temperature °C °F °C×1.8+32
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
• CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
• 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.
Example : 24.5 MPa (250 kgf/cm
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity
To Convert
From
MPa kgf/cm2 10.197 Pressure
MPa psi 145.0
kW PS 1.360 Power
kW HP 1.341
km/h mph 0.6214 Velocity
-1
rpm 1.0
min
2
, 3560 psi)
Into Multiply By
IN-02
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.
001-E01A-0001
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 spe-
cific 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-688
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.
002-E01A-1223
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine
•
and all safety messages in this manual.
Safety signs should be installed, maintained and replaced
•
when necessary.
• 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).
Learn how to operate the machine and its controls correctly
•
and safely.
Allow only trained, qualified, authorized personnel to oper-
•
ate the machine.
Keep your machine in proper working condition.
•
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
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 hazardous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
SA-003
SA-2
SAFETY
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 to 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 fireextinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance service,
hospital, and fire department posted near your telephone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appropri-
•
ate to the job.
SA-437
You may need:
A hard hat
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.
• 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.
005-E01A-0438
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.
006-E01A-0434
SA-3
SA-434
SAFETY
INSPECT MACHINE
Inspect your machine carefully each day or shift by walking
•
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal accident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• 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.
• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.
SA-435
524-E01A-0000
SA-4
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 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, and
handrails when leaving the machine.
SAFETY
008-E01A-0439
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
misoperations.
• The seat should be adjusted whenever changing the operator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT
SA-439
SA-378
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.
SA-5
SAFETY
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.
• 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.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
•
SA-237
• 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). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY
Starting fluid:
Starting fluid is highly flammable.
•
• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-083
SA-293
036-E01A-0293-3
SA-6
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 track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
012-E01B-0431
JUMP STARTING
Battery gas can explode, resulting in serious injury.
•
SA-084
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.
• The operator must be 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.
S013-E01A-0032
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as being struck
•
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-032
014-E01B-0427
SA-7
SA-091
SAFETY
PRECAUTIONS FOR OPERATIONS
Investigate the work site before starting operations.
•
• Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
SA-8
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a road
•
shoulder, the machine could tip over, 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.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
Make sure the worksite has sufficient strength to firmly sup-
•
port the machine.
SA-085
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or 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 on the area.
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 and firm
enough 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. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with machine movements.
M202-05-015
SA-9
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES
SA-686
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.
018-E01A-0481
CONFIRM DIRECTION OF MACHINE TO BE DRIVEN
Incorrect steering wheel/forward/reverse pedal 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 in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.
SA-481
017-E01A-0491
SA-10
SA-092
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the steer-
•
ing wheel/forward/reverse switch 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.
Driving on a slope may cause the machine to slip or over-
•
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 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 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.
SA-090
AVOID INJURY FROM ROLLAWAY ACCIDENTS
Death or serious injury may result if you attempt to mount
•
or stop a moving machine.
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.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-288
SA-278
020-E02A-0493
SA-11
Loading...