Hitachi Industrial Manual (EN)

INTRODUCTION

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. 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 us- age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX:

81-29-831-1162 ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. The Operator’s Manual The Parts Catalog The Engine Manual Parts Catalog of the Engine Hitachi Training Material MANUAL COMPOSITION This manual consists of three portions: the Techni- cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- ual. Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. Information included in the Technical Manual (Troubleshooting):

technical information needed for operational per- formance 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 assem- ble/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

Стр. 3

INTRODUCTION

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. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. 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 appropri- ate lifting techniques and equipment when lifting heavy parts. NOTE: Indicates supplementary technical information or know-how. 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. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees.

IN-02 Quantity To Convert From Into Multiply By Quantity To Convert From Into Multiply By Length mm in 0.03937 Pressure MPa kgf/cm2 10.197 mm ft 0.003281 MPa psi 145.0 Volume L US gal 0.2642 Power kW PS 1.360 L US qt 1.057 kW HP 1.341 m3 yd3 1.308 Temperature °C °F °C×1.8+32 Weight kg lb 2.205 Velocity km/h mph 0.6214 Force N kgf 0.10197 min-1 rpm 1.0 N lbf 0.2248 Flow rate L/min US gpm 0.2642 Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0 N⋅m lbf⋅ft 0.7375

Стр. 4

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL SECTION AND GROUP CONTENTS Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 ECM System Group 3 Hydraulic System Group 4 Electrical System SECTION 3 COMPONENT OPERATION TECHNICAL MANUAL (Operational Principle) Group 1 Pump Device Group 2 Control Valve Group 3 Hydraulic Fan Motor Group 4 Steering Pilot Valve Group 5 Steering Valve Group 6 Pilot Valve Group 7 Charging Block Group 8 Ride Control Valve Group 9 Drive Unit Group 10 Axle Group 11 Brake Valve Group 12 Others All information, illustrations and speci- fications in this manual are based on the latest product information available at the time of publication.

The right is reserved to make changes at any time without notice. TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER- FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Wheel Loader Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Dr.ZX Group 3 e-Wheel Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Troubleshooting C Group 8 Electrical System Inspection COPYRIGHT (C) 2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

Стр. 5

SECTION AND GROUP CONTENTS

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassem- bling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydrau- lic Oil Tank SECTION 2 BASE MACHINE (UPPER STRUCTURE) Group 1 Cab Group 2 Counterweight Group 3 Hood Group 4 Center Hinge Group 5 Hydraulic Oil Tank Group 6 Pump Device Group 7 Control Valve Group 8 Pilot Valve Group 9 Pilot Shutoff Valve Group 10 Hydraulic Fan Motor SECTION 3 BASE MACHINE (TRAVEL SYSTEM) Group 1 Tire Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Charging Block Group 7 Steering Pilot Valve Group 8 Steering Valve Group 9 Steering Cylinder SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

Стр. 6