Hitachi Construction Machinery Service Manual PDF

 INTRODUCTION TO THE READER This manual is written for an experienced technician If you have any questions or comments, at if you to provide technical information needed to maintain found any errors regarding the contents of...

 INTRODUCTION TO THE READER This manual is written for an experienced technician If you have any questions or comments, at if you to provide technical information needed to maintain found any errors regarding the contents of this and repair this machine. manual, please contact using “Service Manual Revision Request Form” at the end of this man- Be sure to thoroughly read this manual for cor- ual. rect product information and service procedures. (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 E-mail: [email protected] This manual contains the revision information to the 13, July 2009. 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 Information included in the Workshop Manual: Workshop Manual. technical information needed for maintenance and repair of the machine, tools and devices Information included in the Technical Manual: needed for maintenance and repair, maintenance technical information needed for redelivery and standards, and removal/installation and assem- delivery, operation and activation of all devices ble/disassemble procedures. and systems, operational performance tests, and troubleshooting 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 CAUTION: signal words are used to alert the reader to the Indicated potentially hazardous situation which potential for personal injury of machine damage. 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. IMPORTANT: Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the along with the safety alert symbol. instructions, could result in damage to the machine. The safety alert symbol is also used to draw attention to component/part weights. NOTE: To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or ate lifting techniques and equipment when lifting know-how. heavy parts. UNITS USED SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi) this manual. MKSA 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 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 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 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 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. 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 ma- SA-1223 chine. NOTE indicates an additional explanation for an element of information. 002-E01A-1223 SA-1  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- SA-003 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, func- tion, 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 equip- ment 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 hazard- ous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your autho- rized dealer before operating or performing maintenance work on the machine. 003-E01B-0003 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 fire- extinguisher manual. Establish emergency procedure guidelines to cope with fires and accidents. Keep emergency numbers for doctors, ambulance service, SA-437 hospital, and fire department posted near your tele- phone. 004-E01A-0437 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropri- ate to the job. 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 ear- muffs or earplugs to protect against objectionable or uncomfortably loud noises. 006-E01A-0434 SA-434 SA-3  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 SA-435 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 ac- cident. 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 at- tach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly start- ing a fire. Refrain from listening to the radio, or using music head- phones 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 tem- perature in the cab increases, the lighter may explode. 524-E01A-0000 SA-4  SAFETY 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 dis- mount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. SA-439 008-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 op- erator 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 SA-378 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 LEAV- ING 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. 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 opera- tor may be crushed by the overturning machine, resulting in serious injury or death. Prior to operating the machine, thoroughly examine web- bing, buckle and attaching hardware. If any item is dam- aged 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. SA-237 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. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or oper- ating the machine. Always keep the travel alarm and horn in working condi- tion (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. SA-083 Use appropriate illumination. Check that all lights are op- erable before operating the machine. If any faulty illumi- nation 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 pressur- ized 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-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. SA-084 012-E01B-0431 JUMP STARTING Battery gas can explode, resulting in serious injury. If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chap- ter 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. SA-032 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. 014-E01B-0427 SA-091 SA-7  SAFETY PRECAUTIONS FOR OPERATIONS Investigate the work site before starting operations. Be sure to wear close fitting clothing and safety equip- ment 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 fall- ing 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 excava- tions and road shoulders. When working on an incline or on a road shoulder, em- SA-085 ploy 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. When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicu- lar 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 M202-05-015 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 ma- chine movements. 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 SA-686 PROVIDE SIGNALS FOR JOBS INVOLVING MUL- TIPLE NUMBERS OF MACHINES 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 SA-481 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-092 017-E01A-0491 SA-10  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- SA-090 turn, possibly resulting in serious injury or death. Never attempt to ascend or descend 35 degrees or steep- er slopes. Be sure to fasten the seat belt. When driving up or down a slope, keep the bucket fac- ing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. If the machine starts to skid or becomes unstable, imme- diately lower the bucket to the ground and stop. SA-288 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 min- utes 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. SA-278 Position the machine to prevent rolling. Park a reasonable distance from other machines. 020-E02A-0493 SA-11  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 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 SA-383 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 con- dition. Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384 decreases, reduce speed and use proper lighting. Read and understand all operating instructions in the operator’s manual. 021-E01A-0494 SA-12  SAFETY KEEP PERSON CLEAR FROM WORKING AREA A person may be hit severely by the swinging front attach- ment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. Keep all persons clear from the area of operation and machine movement. Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent any- one from entering the work area. 022-E01A-0386 M202-05-014 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. 023-E01A-0487 SA-682 AVOID UNDERCUTTING Always confirm that ground conditions are strong enough to support the machine weight when operating near a cliff. Operate the machine with the chassis frame positioned perpendicular to the cliff face so that the machine can more easily evacuate if the cliff face collapses. If the footing starts to collapse and if retreat is not pos- sible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases. 024-E01A-0488 SA-683 SA-13  SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA- CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT 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 ma- SA-088 chine. 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 loads. Be careful when working on frozen ground. Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E03B-0463 SA-684 NEVER UNDERCUT A HIGH BANK The edges could collapse or a land slide could occur causing serious injury or death. 026-E01A-0519 SA-685 SA-14  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 area , and/or the utility companies directly. Have them mark all underground utilities. SA-086 027-E01A-0382 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. 028-E01A-0389 SA-087 SA-15  SAFETY AVOID POWER LINES Serious injury or death can result if the machine or front at- tachments 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 plus twice the line insulator length. Check and comply with any local regulations that may ap- ply. 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-089 029-E01A-0381 PRECAUTIONS FOR LIGHTENING The machine is vulnerable to lighting strikes. In the event of an electrical storm, immediately stop op- eration, 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 repair- ing them. SA-1241 OBJECT HANDLING If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, result- ing in serious injury or death. When using the machine for craning operations, be sure to comply with all local regulations. Do not use damaged chains or frayed cables, sables, slings, or ropes. Before craning, position the upperstructure with the travel motors at the rear. Move the load slowly and carefully. Never move it sud- denly. Keep all persons well away from the load. Never move a load over a person's head. Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0132 SA-014 SA-16  SAFETY PROTECT AGAINST FLYING DEBRIS If flying debris hit eyes or any other part of the body, serious injury may result. Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Keep bystanders away from the working area before strik- ing any object. 031-E01A-0432 SA-432 PARK MACHINE SAFELY To avoid accidents: Park machine on a firm, level surface. Lower bucket to the ground. Place FNR switch in neutral, and put the brake switch in the P (parking brake) position. 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. SA-093 Close 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 spontane- ously. Securely tighten the fuel and oil filler cap. 034-E01A-0496 SA-019 SA-17  SAFETY TRANSPORT SAFELY Take care the machine may turn over when loading or un- loading the machine onto or off of a truck or trailer. Observe the related regulations and rules for safe trans- portation. Select an appropriate truck or trailer for the machine to be transported. Be sure to use a signal person. Always follow the following precautions for loading or unloading: Less than 15° 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the SA-094 machine weight. 3. Turn auto-idle switch OFF. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the travel- ing direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 7. The top end of the ramp where it meets the flatbed is a Less than 15° sudden bump. Take care when traveling over it. SA-095 8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANS- PORTING section. 035-E07A-0454 SA-18  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. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 min- utes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving SA-028 the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. If a maintenance procedure must be performed with the engine running, do not leave machine unattended. If the machine must be raised, maintain a 90 to 100˚ angle between the boom and arm. Securely support any ma- chine elements that must be raised for service work. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the SA-527 “MAINTENANCE” chapter in the operator’s manual. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine. 500-E02C-0520 SA-19  SAFETY 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 on the control lever. This tag is available from your authorized dealer. 501-E01A-0287 SS3076175 SS2045102 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. Do not sup- port the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. SA-527 519-E01A-0527 STAY CLEAR OF MOVING PARTS Entanglement in moving parts can cause serious injury. 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. 502-E01A-0026 SA-026 SA-20  SAFETY PREVENT PARTS FROM FLYING Travel reduction gears are under pressure. As pieces 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 AIR RELEASE PLUG to release pressure. 503-E01B-0344 SA-344 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. Keep children and bystanders away from storage areas. 504-E01A-0034 SA-034 SUPPORT MAINTENANCE PROPERLY Explosive separation of a tire and rim parts can cause seri- ous injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. When inflating tires, use a chip-on chuck and exten-sion hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and SA-249 may result in tire explosion. 521-E02A-0249 SA-21  SAFETY 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 avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pres- sure to be released before removing the cap. SA-039 The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: Engine oil, gear oil and hydraulic oil also become 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-225 505-E01B-0498 REPLACE RUBBER HOSES PERIODICALLY Rubber hoses that contain flammable fluids 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 inspection alone. Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” 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 SA-019 person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019 SA-22  SAFETY 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 disconnect- ing hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard; take care 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 SA-031 must be surgically removed within a few hours or gan- grene may result. 507-E03A-0499 SA-292 SA-044 SA-23  SAFETY PREVENT FIRES Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires. Check for oil leaks due to 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. Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes, or hoses. SA-019 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.. Clean up 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. Check Key Switch: If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the ma- chine 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 stops. If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019 Check Heat Shields: Damaged or missing heat shields may lead to fires. Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393 SA-24  SAFETY EVACUATING IN CASE OF FIRE If a fire breaks out, evacuate the machine in the following way: Stop the engine by turning the key switch to the OFF position if there is time. Use a fire extinguisher if there is time. Exit the machine. In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. SA-393 Refer the explanation pages on the Emergency Evacuation Method. 18-E02B-0393 SS-1510 BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sick- ness or death. If you must operate in a building, be sure there is ad- equate 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. 509-E01A-0016 SA-016 PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and/or small fires. Be sure to perform welding in a well ventilated and pre- pared 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 fire hazards. 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-818 523-E01A-0818 SA-25  SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pres- surized 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 SA-030 FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flam- mable fluids. Clean them thoroughly with nonflammable solvent be- fore welding or flame cutting them. 510-E01B-0030 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. Avoid potentially toxic fumes and dust. Do all such work outside or in a well-ventilated area. Dis- pose of paint and solvent properly. 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 SA-029 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-26  SAFETY BEWARE OF ASBESTOS DUST Take care not to inhale dust produced in the work site. Inha- lation 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 asbes- tos 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. Asbestos might be present in imitation parts. Use only SA-029 genuine Hitachi Parts. 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 elec- trolyte level is lower than specified. Explosion of the bat- tery may result. Loose terminals may produce sparks. Securely tighten all SA-032 terminals. Battery electrolyte is poisonous. If the battery should ex- plode, battery electrolyte may be splashed into eyes, pos- sibly resulting in blindness. Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032 SERVICE AIR CONDITIONING SYSTEM SAFELY If spilled onto skin, refrigerant may cause a cold contact burn. Refer to the instructions described on the container for proper use when handling the refrigerant. Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. Never touch the refrigerant. 513-E01A-0405 SA-405 SA-27  SAFETY HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your ma- chine include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific de- tails on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazard- ous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow proce- dures and use recommended equipment. SA-309 See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environ- ment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to SA-226 recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer. 516-E01A-0226 SA-28  SAFETY BEFORE RETURNING THE MACHINE TO THE CUS- TOMER After maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems. Worn or damaged parts have been repaired or replaced S517-E01A-0435 SA-435 SA-29  SAFETY (Blank) SA-30  SECTION AND GROUP SECTION 4 OPERATIONAL PER- CONTENTS FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test TECHNICAL MANUAL SECTION 5 TROUBLESHOOTING (Troubleshooting) Group 1 Diagnosing Procedure Group 2 Monitor Unit Group 3 Dr. ZX Group 4 ICF Group 5 Component Layout Group 6 Troubleshooting A Group 7 Troubleshooting B Group 8 Electrical System Inspection TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Control Valve SECTION 2 SYSTEM Group 4 Pilot Valve Group 1 Controller Group 5 Electric Lever Group 2 Control System Group 6 Transmission Group 3 ECM System Group 7 Axle All information, illustrations and speci- Group 4 Hydraulic System Group 8 Travel Motor fications in this manual are based on Group 5 Electrical System Group 9 Signal Control Valve the latest product information available Group 10 Steering Valve at the time of publication. The right is Group 11 Brake Valve reserved to make changes at any time Group 12 Others (Upperstructure) without notice. Group 13 Others (Undercarriage) COPYRIGHT(C)2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved ←これ以下 記載しない WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE Group 1 Precautions for Disassem- Group 1 Swing Bearing bling and Assembling Group 2 Travel Motor Group 2 Tightening Torque Group 3 Center Joint Group 3 Painting Group 4 Transmission Group 4 Bleeding Air from Hydrau- Group 5 Axle lic Oil Tank Group 6 Axle Lock Cylinder SECTION 2 UPPERSTRUCTURE Group 7 Operate Check Valve Group 1 Cab (Axle Lock Cylinder) Group 2 Counterweight SECTION 4 FRONT ATTACHMENT Group 3 Main Frame Group 1 Front Attachment Group 4 Pump Device Group 2 Cylinder Group 5 Control Valve Group 3 Hose Rupture Valve Group 6 Swing Device Group 4 Operate Check Valve Group 7 Pilot Valve (Blade/Outrigger) Group 8 Electric Lever Group 9 Pilot Shut-Off Solenoid Valve Group 10 Signal Control Valve Group 11 Travel Shockless Valve Group 12 Swing Shockless Valve Group 13 Solenoid Valve Group 14 Steering Valve Group 15 Brake Valve Group 16 Accumulator Charging Valve  SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 5 Component Test Operational Performance Tests................... T4-1-1 Primary Pilot Pressure..................................T4-5-1 Preparation for Performance Tests.............. T4-1-2 Secondary Pilot Pressure.............................T4-5-3 Solenoid Valve Set Pressure........................T4-5-4 Group 2 Standard Main Pump Delivery Pressure......................T4-5-6 Performance Standard................................. T4-2-1 Main Relief Set Pressure..............................T4-5-8 Main Pump P-Q Diagram............................. T4-2-6 Relief Pressure (When relieving Swing).... T4-5-10 Sensor Activating Range.............................. T4-2-8 Overload Relief Valve Set Pressure.......... T4-5-12 Group 3 Engine Test Main Pump Flow Rate Measurement........ T4-5-14 Engine Speed............................................... T4-3-1 Swing Motor Drainage............................... T4-5-24 Engine Compression Pressure.................... T4-3-4 Steering Valve Relief Pressure.................. T4-5-26 Valve Clearance........................................... T4-3-6 Brake Pressure (Front and Rear).............. T4-5-28 Lubricant Consumption................................ T4-3-9 Brake Accumulated Pressure.................... T4-5-30 Brake Warning Set Pressure (Decrease).. T4-5-32 Group 4 Excavator Test Brake Warning Set Pressure (Increase).... T4-5-34 Travel Speed................................................ T4-4-1 Service Brake Function................................ T4-4-3 Parking Brake Control Function................... T4-4-4 Swing Speed................................................ T4-4-5 Swing Function Drift Check.......................... T4-4-6 Swing Motor Leakage.................................. T4-4-8 Maximum Swingable Slant Angle................ T4-4-9 Swing Bearing Play.................................... T4-4-10 Hydraulic Cylinder Cycle Time................... T4-4-12 Dig Function Drift Check............................ T4-4-14 Control Lever Operating Force.................. T4-4-15 Control Lever Stroke.................................. T4-4-16 Combined Operation of Boom Raise/Swing Function Check........................................ T4-4-17 CEBT-4-1 (Blank) CEBT-4-2  OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quan- The machine performance does not always deteriorate titatively check all system and functions on the ma- as the working hours increase. However, the machine chine. performance is normally considered to reduce in pro- portion to the increase of the operation hours. Accord- Purpose of Performance Tests ingly, restoring the machine performance by repair, 1. To comprehensively evaluate each operational adjustment, or replacement shall consider the number function by comparing the performance test data of the machine’s working hours. with the standard values. 2. According to the evaluation results, repair, adjust, Definition of “Performance Standard” or replace parts or components as necessary to 1. Operation speed values and dimensions of the restore the machine’s performance to the desired new machine. standard. 2. Operational performance of new components 3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be timal conditions. indicated as necessary. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the op- erational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evalu- ate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions. T4-1-1  OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 300 m (984 ft 3 in), and to make a full swing with the front attachment ex- tended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among cowork- T105-06-01-003 ers. Once the test is started, be sure to commu- nicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance T212-07-01-003 to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary. T4-1-2  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Standard The performance standard values are listed in the table * The standard measurement conditions are as follows. below.  Engine Control Dial: Fast Idle For details including measuring method, refer to T4-3  Power Mode Switch: P mode onward.  Auto-Idle Switch: OFF The value indicated in parentheses is only a reference.  Work Mode: Digging mode  Engine Speed Control Mode Selection Switch: Dial mode  Hydraulic Oil Temperature: 50±5 ˚C (122±9 ˚F) Performance Reference Descriptions Remarks Standard Page ENGINE SPEED min-1 T4-3-1 Slow Idle Speed 900±100 Value indicated on Dr. ZX. Fast Idle Speed 1700±50  Fast Idle Speed (with ECO deactivated) 1800±50  Fast Idle Speed (Relief operation) Arm roll-in relief control. Value 1800±50 indicated on Dr. ZX. Fast Idle Speed (E mode) 1600±50 Value indicated on Dr. ZX. Fast Idle Speed (HP mode, Relief operation) Arm roll-in relief control. Value 2000±50 indicated on Dr. ZX. Slow Idle Speed (Pedal mode) Travel speed mode switch: Fast speed 1100±50 Brake switch: OFF or Axle lock Jack up and measure. Value indicated on Dr. ZX. Fast Idle Speed (Pedal mode, Working accelerator) FNR switch: N Brake switch: OFF, Auto axle 2000±50 lock or Axle lock Value indicated on Dr. ZX. Fast Idle Speed (Pedal mode, Relief operation) Travel speed mode switch: Fast speed Brake switch: OFF, Auto axle lock or Axle lock 2200±50 Depress the brake pedal, perform travel relief or jack up and measure. Values indicated on Dr. ZX. Auto-Idle Speed 1100±100 Value indicated on Dr. ZX. Warming-Up Speed 1400±100  ENGINE COMPRESSION PRESSURE 3.04±0.2 Engine speed: at 200 min-1 T4-3-4 MPa (kgf/cm2, psi) (31±2, 440) VALVE CLEARANCE (IN, EX) mm 0.15 With engine cold T4-3-6 LUBRICANT CONSUMPTION Hour meter: 2000 hours or less T4-3-9 mL/h 30 or less (Rated Output) T4-2-1  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Reference Standard Page TRAVEL SPEED km/h (100 m) T4-4-1 Fast Engine speed control mode 35.0+1.0-3.0 selection switch: Pedal mode, Travel speed mode switch: Fast Slow Engine speed control mode selection switch: Pedal mode, 8.6±0.5 Travel speed mode switch: Slow Creeper ZX140W-3: Up to serial No 005000, ZX140W-3-AMS: Up to 2.2±0.3 serial No 050000 Engine speed control mode selection switch: Creeper mode ZX140W-3: Serial No 005001 and up, ZX140W-3-AMS: Serial 1.8±0.3 No 050001 and up Engine speed control mode selection switch: Creeper mode SERVICE BRAKE FUNCTION N (kgf ) T4-4-3 Service Brake Tire lock Parking Brake Tire lock PARKING BRAKE FUNCTION mm/5 min (0) T4-4-4 SWING SPEED sec/3 rev 13.1±1.5 Bucket: empty T4-4-5 SWING FUNCTION DRIFT CHECK mm/90 ˚ 720 or less Bucket: empty T4-4-6 SWING MOTOR LEAKAGE mm/5 min 0 Bucket: loaded T4-4-8 MAXIMUM SWINGABEL SLANT ANGLE deg. 18 or more Bucket: loaded T4-4-9 SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-10 HYDRAULIC C YLINDER CYCLE TIME 2.52 m arm T4-4-12 sec 0.3 m3 (PCSA heaped) bucket, Bucket: empty, Without HRV Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3 Boom Lower (Monoblock Boom) 4.5±0.3 Without bucket: 4.3±0.3 Boom Raise (2-Piece Boom) 2.8±0.3 Without bucket: 3.1±0.3 Boom Lower (2-Piece Boom) 3.0±0.3 Without bucket: 3.3±0.3 Arm Roll-In 3.7±0.3 Without bucket: 3.9±0.3 Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3 Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3 Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3 Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5 Positioning Retract 5.1±0.4 Without bucket: 5.1±0.4 Blade Raise 2.0±0.3 Blade Lower 2.5±0.3 Outrigger Raise 1.9±0.3 Outrigger Lower 1.9±0.3 fNOTE: HRV: Hose Rupture Valve T4-2-2  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-12 sec 0.3 m3 (PCSA heaped) bucket, Bucket: empty, With HRV Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3 Boom Lower (Monoblock Boom) 3.0±0.3 Without bucket: 3.3±0.3 Boom Raise (2-Piece Boom) 4.5±0.3 Without bucket: 4.3±0.3 Boom Lower (2-Piece Boom) 3.2±0.3 Without bucket: 4.1±0.3 Arm Roll-In 3.9±0.3 Without bucket: 4.1±0.3 Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3 Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3 Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3 Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5 Positioning Retract 5.3±0.4 Without bucket: 5.3±0.4 Blade Raise 2.0±0.3 Blade Lower 2.5±0.3 Outrigger Raise 1.9±0.3 Outrigger Lower 1.9±0.3 DIG FUNCTION DRIFT CHECK 2.52 m arm T4-4-14 (Maximum Reach Position) mm/5 min 0.3 m3 (PCSA heaped) bucket, bucket loaded Boom Cylinder 5 or less Arm Cylinder 10 or less Bucket Cylinder 15 or less Positioning Cylinder 15 or less Front Drift Amount (Bucket Bottom) 100 or less CONTROL LEVER OPERATING FORCE N (kgf ) T4-4-15 Right Lever: Forward/Backward 15 (1.5) or less Right Lever: Right/Left 15 (1.5) or less Left Lever: Forward/Backward 15 (1.5) or less Left Lever: Right/Left 15 (1.5) or less Steering Wheel Turns (lock-to-lock) 20 (2.0) or less CONTROL LEVER STROKE mm T4-4-16 Right Lever: Forward/Backward 62±10 Right Lever: Right/Left 62±10 Left Lever: Forward/Backward 74±10 Left Lever: Right/Left 74±10 Steering Wheel Turns (lock-to-lock) 7.0±0.5 2.52 m arm T4-4-17 COMBINED OPERATION OF BOOM sec 3.6±0.3 0.3 m3 (PCSA heaped) bucket, RAISE/SWING FUNCTION CHECK Bucket: empty Bucket Teeth Height: H mm 5500 or more fNOTE: HRV: Hose Rupture Valve T4-2-3  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE T4-5-1 MPa (kgf/cm2, psi) 4.0+1.0-0.5 Fast Idle (41 -5, 581+145-73) +10 SECONDARY PILOT PRESSURE 3.3 to 3.9 Value indicated on Dr. ZX. T4-5-3 (For Fast Idle, Slow Idle) (34 to 40, (Control lever: Full stroke) MPa (kgf/cm2, psi) 480 to 567) STEERING PUMP PRESSURE 2.5±1.0 MPa (kgf/cm2, psi) (26±10, 363±145) SOLENOID VALVE SET PRESSURE T4-5-4 MPa (kgf/cm2, psi) Solenoid Valve Unit Set Pressure (Value of Dr. ZX) ±0.2 Value indicated on Dr. ZX. (2, 29) MAIN PUMP DELIVERY PRESSURE 1.0+1.0-0.5 In neutral, Value indicated T4-5-6 MPa (kgf/cm2, psi) (10+10 , 145+145 ) on Dr. ZX -5.0 -73 MAIN RELIEF VALVE RELIEF PRESSURE T4-5-8 MPa (kgf/cm2, psi) Boom, Arm, Bucket (Relief operation for each) 34.3+1.2-0.8 Value indicated on Dr. ZX. (350+12-8, 4980+175-115) RELIEF PRESSURE MPa (kgf/cm2, psi) Relief operation of swing 33.4+2.3-0.5 Value indicated on Dr. ZX. T4-5-10 (340+23-5, 4860+335-73) Relief operation of travel 35.3+2.0-1.0 Value indicated on Dr. ZX. (360 -10, 5130 -145) +20 +290 Relief operation of blade/outrigger raise 28.0+2.0-0 Value indicated on Dr. ZX. (285+20-0, 4070+290-0) Relief operation of blade/outrigger 28.0+2.0-1.0 Value indicated on Dr. ZX. lower (285 -10, 4070 -145) +20 +290 OVERLOAD RELIEF VALVE RELIEF PRESSURE T4-5-12 MPa (kgf/cm2, psi) Boom (lower), Arm (roll-in), Bucket (roll-in), (Reference values at 50 L/ 37.2 (379, 5410) Blade/Outrigger (raise/lower) min) Boom (raise), Arm (roll-out), Bucket (roll-out) (Reference values at 50 L/ 39.2 (400, 5700) min) (Reference values at 135 Auxiliary 28.0 (285, 4070) L/min) T4-2-4  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page MAIN PUMP FLOW RATE L/min - Refer to T4-2-6. T4-5-14 SWING MOTOR DRAINAGE L/min With constant speed 0.2 to 0.3 T4-5-24 With motor relieved (2 to 5) STEERING VALVE RELIEF PRESSURE 17.5±1.0 T4-5-28 MPa (kgf/cm2, psi) (179±10, 2540±145) BRAKE PRESSURE (FRONT/REAR) 7.0±1.0 T4-5-30 (including work brake operating pressure) (70±10, MPa (kgf/cm2, psi) 1020±145) BRAKE ACCUMULATOR PRESSURE 17.7±1.0 T4-5-32 MPa (kgf/cm2, psi) (181±10, 2570±145) BRAKE ALARM PRESSURE MPa (kgf/cm2, psi) Decrease 8.3±0.3 T4-5-34 (85±3, 1210±44) 9.0±0.3 T4-5-36 Increase (92±3, 1310±44) T4-2-5  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram  Hydraulic P-Q Control (Torque Control) (NOTE: Measured at Test Stand)  Rated Pump Speed: 2200 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) fNOTE: Refer to T4-5-14. P-Q Point Delivery Pressure Flow Rate MPa (kgf/cm2, psi) L/min (gpm) Pump 1: 220±3 A 3.9 (40, 570) (58.0±0.8) Pump 2: 165±3 A’ 3.9 (40, 570) (43.5±0.8) B 11.8 (120, 1720) Pump 1: [218 (57.5)] B’ 16.7 (170, 2430) Pump 2: [163 (43.0)] C 18.6 (190, 2700) 147±6 (38.8±1.6) D 20.6 (210, 2990) [125 (33.0)] E 22.5 (230, 3270) 110±6 (29.0±1.6) F 34.3 (350, 4990) 53±10 (14.0±2.6) The value indicated in parentheses is only a reference. L/min A B A’ B’ C D Flow Rate E F Delivery Pressure MPa (kgf/cm2) TCEB-04-02-001 T4-2-6  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard  P-Q Control by Pump Control Pilot Pressure Signal (NOTE: Measured at Test Stand)  Rated Pump Speed: 2200 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) fNOTE: Refer to T4-5-16. P-Q Point Pump Control Pressure Flow Rate MPa (kgf/cm2, psi) L/min (gpm) 1.9±0.05 (19±0.5, Pump 1: 91±2 (24.0±0.5) A 276±7.3) Pump 2: 70±2 (18.5±0.5) 3.4±0.05 (35±0.5, B 129±8 (34.0±2.1) 494±7.3) Pump 1: 220±3 2.9+0.05-0.29 (58.0±0.8) C (30 -3, 422+7.3-42.2) +0.5 Pump 2: 165±3 (43.5±0.8) fNOTE: B: With flow rate limit control C: Without flow rate limit control L/min C B Flow Rate A Pump Control Pressure MPa (kgf/cm2, psi) T1T1-04-02-001 T4-2-7  SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Measuring Method  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Unless specified: Power Engine Auto-Idle Mode Work Mode Control Dial Switch Switch Fast Idle Digging P OFF Speed mode  Monitor each sensor by using Dr. ZX. 2. Sensor Activating Range Item Operation Standard Slow Idle 0.3 to 1.0 V Engine Control Dial Fast Idle 4.0 to 4.7 V Control lever: Neutral position 0 to 0.1 MPa Pressure Sensor Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi) (Boom Raise, Arm Roll-In, Swing) Control lever: Full stroke 3.3 to 3.9 MPa Pilot shut-off lever: UNLOCK position (34 to 40 kgf/cm2, 480 to 570 psi) Control Lever: Neutral position 0 to 0.1 MPa Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi) Pressure Sensor (Travel) Control lever: Full stroke 2.7 to 3.3 MPa Pilot shut-off lever: UNLOCK position (28 to 34 kgf/cm2, 390 to 480 psi) 0.7 to 1.3 MPa Control lever: Neutral position (7 to 13 kgf/cm2, 100 to 190 psi) Pump Control Pressure Sensor 2.9 to 3.9 MPa Control lever: Full stroke (30 to 40 kgf/cm2, 420 to 570 psi) Travel N Sensor 20 °C (GND to SIGNAL) 810±240 Ω T4-2-8  OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary: 1. Measure the engine speed by using the monitor unit or Dr. ZX. 2. Measure the engine speeds in each mode. NOTE: If the engine speed is not adjusted correctly, all other performance data will be unreliable. Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets specification. Preparations: 1. Select the service menu of monitor (In case of Dr. ZX, install Dr. ZX first). 2. Warm up the machine until coolant temperature reaches 50 °C (122 °F) or more, and hydraulic oil temperature is 50±5 °C (122±9 °F). T4-3-1  OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: Remedy: 1. Measure the engine speeds in the "dial mode" and Refer to Troubleshooting B in Group T5-7. "pedal mode" positions for the engine speed control mode selection switch. NOTE: ECO stands for the auto engine speed 2. When measuring, set the switch and test condition -1 reduction system by 100 min. as shown in the table below in response to the engine speed to be measured. Evaluation: Refer to OPERATIONAL PERFORMANCE TEST / Standard in Group T4-2. Engine Speed Control Mode Selection Switch: Dial mode Engine Power Auto- Item Control Mode Idle Work Mode Test Conditions Dial Switch Switch Slow Idle Digging Lever in neutr