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-0001
SA-001
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
S007-E01A-0435
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
008-E01A-0439
009-E01A-0378
SA-4
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
Starting fluid:
JUMP STARTING
S013-E01A-0032
SA-6
SAFETY
KEEP RIDERS OFF MACHINE
SA-379
014-E01B-0379
SA-481
018-E01A-0481
SA-7
SAFETY
DRIVE MACHINE SAFELY
SA-388
SA-441
SA-589
S019-E02B-0590
SA-8
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 off. SA-391
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 tracks 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.
020-E02A-0493 SA-392
SA-9
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-10
SAFETY
AVOID TIPPING
To avoid tipping:
Be extra careful before operating on a grade.
S025-E02B-0495
SA-11
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-12
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle 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
position.
Close windows, roof vent, and cab door. SA-390
Lock all access doors and compartments.
033-E02B-0390
SA-13
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
034-E01A-0496 SA-019
SA-14
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-15
SAFETY
WARN OTHERS OF SERVICE WORK
S501-E01A-0287
SA-287
519-E01A-0527
502-E01A-0026 SA-026
SA-16
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-17
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
505-E01B-0498
506-E01A-0019
SA-18
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E01A-0499 SA-044
SA-19
SAFETY
PREVENT FIRES
Clean up Flammables:
SA-20
SAFETY
Check Emergency Engine Stop Switch:
S518-E01A-0393
SA-21
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016 SA-016
510-E01B-0030
SA-22
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01B-0032
SA-23
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
SA-24
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
S516-E01A-0226
SA-25
SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
S517-E01A-0435 SA-435
SA-26
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
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
18CW-1-1
(Blank)
18CW-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
T142-05-03-008
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
TIGHTENING TORQUE SPECIFICATION
Torque Specifications
Bolt Dia Wrench Torque
No. Descriptions Qty
(mm) Size (mm) Nm (kgf m) (lbf ft)
1 Engine cushion rubber mounting bolt 36 6 55 3140 (320) (2320)
Engine bracket mounting bolt
27 12 41 1030 (105) (760)
2 (Flywheel housing side)
Engine bracket mounting bolt (Fan side) 20 10 30 390 (40) (290)
3 Hydraulic oil tank mounting bolt 30 8 46 1420 (145) (1050)
4 Fuel tank mounting bolt 30 15 46 1420 (145) (1050)
5 Pump transmission mounting bolt 12 16 19 88 (9) (65)
Pump mounting bolt (Main pump) 20 12 30 540 (55) (400)
6
Pump mounting bolt (Fan pump) 20 4 17 540 (55) (400)
7 Gear pump mounting bolt 12 4 19 88 (9) (65)
8 Control valve mounting bolt 16 12 24 265 (27) (195)
9 Swing device mounting bolt 33 48 50 2550 (260) (1880)
10 Swing motor mounting bolt 20 8 30 390 (40) (290)
11 Battery mounting bolt 10 16 17 49 (5) (36)
12 Cab mounting bolt 18 10 27 280 (29) (210)
13 Cab bed mounting bolt 16 40 24 265 (27) (195)
Swing bearing mounting bolt (Upperstructure) 45 58 70 4700 (480) (3470)
14
Swing bearing mounting bolt (Track) 45 60 70 4700 (480) (3470)
15 Counterweight mounting bolt 45 6 75 3920 (400) (2890)
16 Engine bed mounting bolt 30 20 30 1420 (145) (1050)
17 Oil cooler mounting bolt 27 4 41 1370 (140) (1010)
18 Radiator mounting bolt 27 4 41 1370 (140) (1010)
19 Fan motor mounting bolt 16 4 24 205 (21) (152)
20 Fan motor bracket mounting bolt 12 6 19 88 (9) (65)
21 Travel motor mounting bolt 20 8 30 390 (40) (290)
22 Upper roller mounting bolt 20 25 30 390 (40) (290)
23 Lower roller mounting bolt 30 64 46 1910 (195) (1410)
Travel device mounting bolt (A) 22 32 32 740 (75) (540)
24 Travel device mounting bolt (B) 33 64 50 2550 (260) (1880)
Travel device mounting bolt (C) 30 60 46 1910 (195) (1410)
25 Sproket mounting bolt 30 30 46 1910 (195) (1410)
26 Track guard mounting bolt 30 12 46 1910 (195) (1410)
27 Track shoe bolt 33 392 50 3190 (325) (2350)
28 Side frame mounting bolt 45 68 70 4710 (480) (3470)
Front pin-retaining bolt (Loader) 20 32 30 390 (40) (290)
29 Front pin-retaining bolt (Loader) 16 4 24 205 (21) (152)
Front pin-retaining bolt (Loader) 24 4 36 690 (70) (510)
Front pin-retaining bolt (Backhoe) 20 24 30 390 (40) (290)
30
Front pin-retaining bolt (Backhoe) 16 12 24 205 (21) (152)
W1-2-1
GENERAL / Tightening
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before instal-
lilng and tightening swing bearing mounting
bolts and lower roller mounting bolts.
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.2) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.4) (135) 140 (14.3) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.2) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.3) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (199) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (199) (1440) 750 (76.5) (550)
M36 55 27 3200 (326) (2360) 2450 (250) (1810) 950 (97.0) (700)
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
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
Preparation
T142-05-03-007
T142-05-03-008
Hexagon Wrench
W118-02-03-018
W1-3-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
Vacuum
2
1. Bleed air from hydraulic oil tank. 3
(Refer to Bleeding Air from Hydraulic Oil Tank on 1
page W1-3-1) Port
Hydraulic Oil
Tank
W141-01-03-001
W1-3-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Disassemble Air Compressor
Dimensions of the Cab Glass .............. W2-1-1 Drive Pump and Pilot Pump ............. W2-4-86
Assemble Air Compressor
Group 2 Counterweight Drive Pump and Pilot Pump ............. W2-4-92
Remove and Install Counterweight ...... W2-2-1 Maintenance Standard....................... W2-4-96
Disassemble Lubrication Pump
Group 3 Main Frame for Pump Transmission .................... W2-4-98
Remove and Install Main Frame .......... W2-3-1 Assemble Lubrication Pump
for Pump Transmission .................. W2-4-100
Group 4 Pump Device Maintenance Standard..................... W2-4-102
Remove and Install Pump Device ........ W2-4-1
Disassemble Pump Transmission...... W2-4-22 Group 5 Control Valve
Assemble Pump Transmission .......... W2-4-26 Remove and Install Control Valve ........ W2-5-1
Disassemble Main Pump ................... W2-4-30 Disassemble Control Valve .................. W2-5-5
Assemble Main Pump........................ W2-4-38 Assemble Control Valve..................... W2-5-12
Maintenance Standard ...................... W2-4-46 Disassemble and Assemble Main Relief
Disassemble Regulator Valve and Overload Relief Valve ........ W2-5-16
for Main Pump ................................. W2-4-48 Make-Up Valve Construction ............. W2-5-18
Assemble Regulator for Main Pump .. W2-4-54
Components of 4-Spool Pump........... W2-4-61 Group 6 Swing Device
Disassemble Oil Cooler Fan Remove and Install Swing Device........ W2-6-1
Drive Pump ..................................... W2-4-62 Disassemble Swing Reduction Gear .... W2-6-4
Assemble Oil Cooler Fan Assemble Swing Reduction Gear....... W2-6-12
Drive Pump ..................................... W2-4-66 Disassemble Swing Motor ................. W2-6-22
Maintenance Standard ...................... W2-4-72 Assemble Swing Motor ...................... W2-6-26
Disassemble Regulator Maintenance Standard....................... W2-6-30
for Oil Cooler Fan Drive Pump ......... W2-4-74 Disassemble and Assemble
Assemble Regulator Valve Unit ........................................ W2-6-32
for Oil Cooler Fan Drive Pump ......... W2-4-80
18CW-2-1
Group 7 Pilot Valve Group 13 Compressor Drive Motor
Remove and Install Remove and Install
Front/Swing Pilot Valve ...................... W2-7-1 Compressor Drive Motor.................. W2-13-1
Remove and Install Travel and Disassemble Compressor
Bucket Open/Close Pilot Valve .......... W2-7-3 Drive Motor...................................... W2-13-4
Pilot Line Connection .......................... W2-7-6 Assemble Compressor Drive Motor ... W2-13-6
Disassemble Front/Swing Pilot Valve... W2-7-8
Assemble Front/Swing Pilot Valve ..... W2-7-10 Group 14 Air Conditioner
Disassemble Travel Work after Replacing Component ...... W2-14-1
Bucket Open/Close Pilot Valve ........ W2-7-14 Add Compressor Oil .......................... W2-14-1
Assemble Travel Charge Air Conditioner
Bucket Open/Close Pilot Valve ........ W2-7-16 with Refrigerant ............................... W2-14-2
18CW-2-2
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