Hitachi ex750 5 excavator service repair manual
- 2. 162W-1-1 SECTION 1 GENERAL IMFORMATION ; ; ; ;CONTENTS; ; ; ; Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology.......................................... W1-1-4 Group 2 Tightening Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5
- 3. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-1 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling • Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. • Inspect the Machine Be sure to thoroughly understand all disassembling /assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts. • Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. • Precautions for Disassembling • To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place it on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances. • Precautions for Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace it. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no tools are missing.
- 4. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-2 Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and install ation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: • Bleeding Air from Hydraulic Pump IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. Be sure to bleed air before starting the engine. • 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 engine 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. • Bleeding Air from Travel Motor/Swing Motor • With the drain plug/hose on travel motor/swing motor removed, fill the motor case with hydraulic oil. • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary. M104-07-021
- 5. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-3 Floating Seal Precautions 1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check seal ring face (C) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean floating seal (A) and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. (2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal face (C) is parallel with seal mounting bores ring face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating. W105-03-05-019 W105-03-05-020 W110-03-05-004 Correctly Incorrectly A B a b a=b a≠b a b Correctly Incorrectly D C B
- 6. GENERAL INFORMATION / Precautions for Disassembling and Assembling W1-1-4 MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of components or assemblies adjusted to specification. Both dimensions are shown with tolerances as necessary. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or replacement is required before reaching this limit. Machine performance will decrease, and maintenance and down time expense will increase as machine operating hours accumulate. It is recommended that parts are repaired or replaced before reaching the “Allowable Limit”.
- 7. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-1 TIGHTENING TORQUE SPECIFICATIONS Bolt Dia Wrench Size Torque No. Descriptions mm Q’ty (mm) N⋅m kgf⋅m lbf⋅ft Engine cushion rubber 16 2 24 265 27 195 Front Cushion rubber-machine 16 2 24 265 27 195 Engine cushion rubber 24 2 36 690 70 510 1 Engine cushion rubber mount- ing bolt Rear Cushion rubber-machine 18 4 27 390 40 290 2 Muffler bracket mounting bolt UNC 1/2 UNC 3/8 4 6 19 14 88 49 9 5 65 36 3 Radiator mounting bolt 24 4 36 690 70 510 4 Hydraulic oil tank mounting bolt 18 8 27 295 30 215 5 Fuel tank mounting bolt 18 4 27 295 30 215 6 ORS fittings for hydraulic hoses and piping 1-Ӹ -12UNF 41 205 21 152 7 Pump transmission mounting bolt UNC 14 16 69 7 51 8 Pump device mounting bolt 24 4 36 690 70 510 9 Control valve mounting bolt 20 4 30 390 40 290 10 Swing device mounting bolt 24 28 36 930 95 690 11 Swing motor mounting bolt (hexagonal wrench) 20 24 30 390 40 290 12 Battery mounting bolt 12 2 19 34 3.5 25.5 STD 16 4 24 205 21 152 13 Cab mounting bolt H 16 6 24 205 21 152 14 Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage 33 33 30 36 4 40 50 50 46 2160 2160 1720 220 220 175 1590 1590 1270 15 Travel device mounting bolt Travel motor mounting bolt Sprocket mounting bolt 27 18 27 40 8 48 41 27 41 1370 295 1370 140 30 140 1010 215 1010 16 Upper roller mounting 20 24 30 540 55 400 17 Lower roller mounting bolt STD, H 24 72 36 930 95 690 18 Track shoe bolt STD, H 27 408 41 1960 200 1450 19 Track guard mounting bolt STD, H 27 16 41 1370 140 1010 20 Track frame mounting bolt 36 44 55 2750 280 2030 Coupling 8 13 10.5 to 12.5 1.05 to 1.26 7.6 to 9.1 21 Coupling and clamp of low pressure piping Clamp -28UNF 11 5.9 0.6 4.3 22 Counterweight mounting bolt Counterweight retaining bolt 45 24 2 4 65 36 2750 690 280 70 2030 510 23 Front pin-retaining bolt 20 30 30 390 40 290 NOTE: (1) Apply lubricant (e.g. white Zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction coefficient of them. (2) Make sure bolt and nut threads are clean before installing. (3) Apply LOCTITE to threads before installing and tightening swing bearing mounting bolts. 7 16 7 16 1 4
- 8. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-2 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four kinds of bolts, hexagon bolts T, H, M and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. SA-040 W105-01-01-007 Specified Tightening Torque Chart T Bolt, Socket bolt H Bolt M Bolt Bolt Dia. Wrench Size Hexagon Wrench Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2 M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5 M 12 19 10 108 11 80 88 9 65 34 3.5 25.5 M 14 22 12 175 18 130 137 14 101 54 5.5 40 M 16 24 14 265 27 195 205 21 152 78 8 58 M 18 27 14 390 40 290 295 30 220 118 12 87 M 20 30 17 540 55 400 390 40 290 167 17 123 M 22 32 17 740 75 540 540 55 400 215 22 159 M 24 36 19 930 95 690 690 70 505 275 28 205 M 27 41 19 1370 140 1010 1030 105 760 390 40 290 M 30 46 22 1910 195 1410 1420 145 1050 540 55 400 M 33 50 24 2550 260 1880 1910 195 1410 740 75 540 M 36 55 27 3140 320 2310 2400 245 1770 930 95 690 Socket Bolt Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt
- 9. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-3 IMPORTANT: (1) Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. (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 sufficient 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 application. (5) Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. W105-01-01-003 Equally tighten upper and lower alternately 1,4 2,3 Tighten diagonally 1 13 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 14 Tighten from center and diagonally
- 10. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-4 Service Recommendations for Split Flange IMPORTANT: (1) Be sure to clean and inspect sealing surfaces. Scratches/ roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. (2) Be sure to use only specified O- rings. Inspect O-rings for any damage. Take care not to file O- ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. (3) Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand- tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. (4) Tighten bolts alternately and diagonally, as shown, to ensure even tightening. (5) Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Lockings • Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. • Lock Wire IMPORTANT: Apply wire to bolts in the bolt- tightening direction, not in the bolt- loosening direction. W105-01-01-015 WRONG W105-01-01-016 W105-01-01-008 W105-01-01-009 W105-01-01-010 Bend along edge sharply Do not bend it round Bend along edge sharply RIGHT WRONG RIGHT RIGHT WRONG Tighten Loosen RIGHT RIGHT WRONG RIGHT WRONG
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- 12. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-5 PIPING JOINT Pipe Thread Connection/Union Joint Tightening Torque Specifications Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: (1) Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications. (2) Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting. M202-07-051 W105-01-01-017 Type Wrench Size Tightening Torque Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft 30° Male Union 19 19 59 6 43 Joint 22 22 98 10 72 27 27 118 12 87 36 36 235 24 134 41 41 295 30 215 50 50 490 50 360 60 60 670 68 490 70 70 980 100 720 37° Female Union 19 17 44 4.5 32.5 Joint 22 19 59 6 43 27 22 118 12 87 36 30ȌȀ32 235 24 134 41 36 295 30 215 50 46 490 50 360 NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint. 1 4 3 5 2 Male Union Joint Female Union Joint 30° or 37° 30° or 37° Joint Body
- 13. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-6 O-ring Seal Joint O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. IMPORTANT: (1) Be sure to replace O-ring (6) with a new one when reconnecting. (2) Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O- ring (6) displaced will damage O- ring (6), resulting in oil leakage. (3) Take care not to damage O-ring groove (8) or sealing face (10). Damage to O-ring (6) will cause oil leakage. (4) If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place. M104-07-033 Wrench Size Tightening Torque Union Nut Joint Body N⋅m kgf⋅m Ibf⋅ft 19 17 59 6 43 22 19 98 10 72 27 22 118 12 87 36 30, 32 235 24 134 41 36 295 30 215 50 46 490 50 360 Joint Body 7 6 9 8 10
- 14. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-7 Screwed-In Connection IMPORTANT: Many types of screwed-in con- nections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. • Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp. T-Bolt Type Band Clamp: 4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft) W105-01-01-018 Male Tapered Thread Wrench Size Tightening Torque Joint Body N⋅m kgf⋅m lbf⋅ft 17, 19 59 6 43 19, 22 98 10 72 27, 22 118 12 87 36, 32 235 24 134 41 295 30 215 50 490 50 360 60 670 68 490 70 980 100 720 W105-01-01-019 M114-07-041 M114-07-042 M114-07-043 PT Male Straight Thread PF ȓȐ° Male Tapered Thread Leave one to two pitch threads uncovered Internal Thread External Thread Clearance Worm Gear Type T-Bolt Type
- 15. GENERAL INFORMATIONȀ Ȁ Ȁ Ȁ/Ȁ Ȁ Ȁ ȀTightening W1-2-8 Connecting Hose CAUTION: (1) When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine. (2) Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. (3) If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects. WRONG RIGHT W105-01-01-011 WRONG RIGHT W105-01-01-012 WRONG RIGHT W105-01-01-013 WRONG RIGHT W105-01-01-014 Rubbing Against Each Other Clamp Clamp Rubbing Rubbing Clamp