Hitachi zaxis 600 excavator service repair manual
- 2. GENERAL / 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 disassem- bling/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 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.
- 3. GENERAL / Precautions for Disassembling and Assembling W1-1-2 • Precautions for Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • 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 forgotten tools remain in the assembled machine. Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and instal- lation of the pump, swing motor, travel motor or cylin- der is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump hous- ing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic mo- tor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine. • Bleeding Air from Hydraulic Pump • 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. • 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.
- 4. GENERAL / Precautions for Disassembling and Assembling W1-1-3 • 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 op- eration (never fully stroke the cylinders during ini- tial 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. Re- plenish oil as necessary. M104-07-021
- 5. GENERAL / Precautions for Disassembling and Assembling W1-1-4 Floating Seal Precautions 1. In general, replace the floating seal with a new one after disassembling. If the floating seal 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. Apply oil to the sliding surface (C) on seal ring (A). (2) Check the slide surface (C) on seal ring (A) 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 the floating seal 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. Check the bore surface for scuffing or scoring by touching the surface. (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 ring surface (C) is parallel with seal mating 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 a b b b a a a=b D C Incorrect Correct Incorrect Correct A B
- 6. GENERAL / Precautions for Disassembling and Assembling W1-1-5 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t dete- riorate with heat, sun light, or chemicals. W102-04-02-016 W105-04-01-008 W162-01-01-009 Correct Eyehole Lifting Method Incorrect Eyehole Lifting Method Bent Sling
- 7. GENERAL / Precautions for Disassembling and Assembling W1-1-6 CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may re- sult. Be sure to visually check the nylon sling for any damage before using. 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. Damaged Appearance W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008 Broken Sewing Thread Scuffing Broken Sewing Thread Fuzz Broken Sewing Thread Separation of Belt Broken Sewing Thread Scuffing Scoring Broken Warp Fuzz
- 8. GENERAL / Precautions for Disassembling and Assembling W1-1-7 MAINTENANCE STANDARD TERMINOL- OGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. “Allowable Limit” 1. Normal machine performance cannot be accom- plished after exceeding this limit. 2. Repair or adjustment is impossible after exceed- ing this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.
- 9. GENERAL / Tightening Torque W1-2-1 TIGHTENING TORQUE SPECIFICATION Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) (lbf ft) Front Cushion rubber - machine 22 2 32 750 (76.5) (550) 1 Engine cushion rubber mount- ing bolt Rear Cushion rubber - machine 33 2 50 1950 (198.5) (1440) 2 Engine bracket mounting bolt 14 8 22 210 (21.5) (155) 3 Radiator mounting bolt 27 4 41 1050 (107.0) (770) 4 Hydraulic oil tank mounting bolt 16 8 24 210 (21.5) (155) 5 Fuel tank mounting bolt 16 8 24 210 (21.5) (155) 6 ORS fittings for hydraulic hoses and piping 1 1 3 16 7 16 12UNF 12UNF 36 41 175 205 (18.0) (21.0) (130) (150) 7 Pump transmission mounting bolt 12 14 19 110 (11.2) (80) 8 Main pump mounting bolt (hexagonal wrench) 20 8 17 550 (56.0) (405) 9 Control valve mounting bolt 20 4 30 400 (41.0) (295) 10 Swing device mounting bolt 22 26 32 750 (76.5) (550) 11 Swing motor mounting bolt (hexagonal wrench) 12 16 10 90 (9.2) (65) 12 Battery mounting nut 12 2 19 35 (3.5) (25) 13 Cab mounting nut 16 6 24 210 (21.5) (155) 14 Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to undercarriage 30 30 36 36 46 46 1950 1750 (198.5) (178.0) (1440) (1290) 15 Travel device mounting bolt Travel motor mounting bolt Sprocket mounting bolt 22 18 22 48 8 48 32 27 32 750 300 750 (76.5) (30.5) (76.5) (550) (220) (550) 16 Upper roller mounting 20 24 30 550 (56.0) (405) STD, H 24 64 36 950 (97.0) (700) 17 Lower roller mounting bolt LC, LCH 24 72 36 950 (97.0) (700) STD, H 24 392 32 1400 (143.0) (1030) 18 Track shoe bolt LC, LCH 24 416 32 1400 (143.0) (550) STD, H 24 16 36 950 (97.0) (700) 19 Track guard mounting bolt LC, LCH 24 24 36 950 (97.0) (700) 20 Track mounting bolt 33 36 50 2200 (224.0) (1620) Continued on next page
- 10. GENERAL / Tightening Torque W1-2-2 Bolt Dia Torque No. Descriptions mm Q’ty Wrench Size (mm) N m (kgf m) (lbf ft) 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 1/4-28 UNF 11 9.8 (1.0) (7.2) 22 Counterweight mounting bolt 45 24 2 4 65 36 2800 450 (285.5) (46.0) (2065) (330) 23 Shuttle valve mounting bolt 10 4 17 50 (5.1) (37) 20 15 30 400 (41.0) (295) 24 Front pin-retaining bolt Front pin-retaining nut 20 7 30 400 (41.0) (295) 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.
- 11. GENERAL / Tightening Torque W1-2-3 TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and proce- dures can create safety hazards. For loosen- ing and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or compo- nents. SA-040 Specified Tightening Torque Chart M552-07-091 Socket Bolt M552-07-090 M157-07-225 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) M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1) 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 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0) M14 22 12 180 (18.5) (135) 140 (14.0) (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 (12.0) (89) M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (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 (200) (1440) 1450 (148) (1070) 550 (56.0) (410) M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550) M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
- 12. GENERAL / Tightening Torque W1-2-4 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. Bolt Tightening Order When tightening two or more bolts, tighten them alter- nately, as shown, to ensure even tightening. W105-01-01-003 1 6 4 2 3 Equally tighten upper and lower alter- Tighten diagonally Tighten from center and diago- 1st to 4th 2nd to 3rd 13 11 10 14 12 7 6 1 4 3 2 5 8 9 5
- 13. GENERAL / Tightening Torque W1-2-5 Service Recommendations for Split Flange IMPORTANT: 1. Be sure to clean and Inspect seal- ing surfaces. Scratches / rough- ness cause leaks and seal wear. Unevenness causes seal extru- sion. If defects cannot be pol- ished out, replace the compo- nent. 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. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and di- agonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tight- ening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Locking • 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 tight- ening, 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 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 Loosen Tighten WRONG RIGHT RIGHT RIGHT WRONG WRONG RIGHT WRONG WRONG RIGHT RIGHT
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- 15. GENERAL / Tightening Torque W1-2-6 PIPING JOINT IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a differ- ent torque is given for a specific ap- plication. Union Joint Metal sealing surfaces (4) and (5) of adapter (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 nut (3). Ex- cessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifi- cations. 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 Wrench Size mm Wrench Size mm Tightening Torque Description Union Nut Hose Fittings N m (kgf m, lbf ft) 30 male 17 17 24.5 (2.5,18) 19 19 29.5 (3.0,21.5) 22 22 39 (4.0,28.5) 27 27 93 (9.5,69) 32 32 137 (14.0,101) 36 36 175 (18.0,129) 41 41 205 (21.0,151) 37 female 17 14 24.5 (2.5,18) 19 17 29.5 (3.0,21.5) 22 19 39 (4.0,28.5) 27 22 93 (9.5,69) 32 27 137 (14.0,101) 36 32 175 (18.0,129) 41 36 205 (21.0,151) NOTE: Tightening torque of 37 male coupling without union is similar to tightening torque of 37 female. 37 30 Female Union Joint Male Union Joint 1 3 5 2 Joint Body 4
- 16. GENERAL / Tightening Torque W1-2-7 O-ring Seal Joint O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening 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 (e) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O- ring (6) is correctly seated in place, tighten nut (9). M104-07-033 Wrench Size mm Wrench Size mm Tightening Torque Union Nut Hose Fittings N m (kgf m, lbf ft) 19 17 29.5 (3.0,21.5) 22 19 69 (7.0,51) 27 22 93 (9.5,69) 32 27 137 (14.0,101) 36 30,32 175 (18.0,129) 41 36 205 (21.0,151) 46 41 205 (21.0,151) 7 6 9 8 10 Hose Fittings
- 17. GENERAL / Tightening Torque W1-2-8 Screw-In Connection Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: 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 leaks 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 and, 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 depend- ing on the type of 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 kg m, 4.3 to 5.1 lbf ft) W105-01-01-018 Male Tapered Thread Wrench Size mm Tightening Torque N m (kgf m, lbf ft) Hose Fittings FC material SS material 19 14.5 (1.5,10.5) 34 (3.5,25) 22 29.5 (3.0,21.5) 49 (5.0,36) 27 49 (5.0,36) 93 (9.5,69) 36 69 (7.0,51) 157 (16,116) 41 108 (11,80) 205 (21,151) 50 157 (16,116) 320 (33,235) 60 195 (20,144) W105-01-01-019 M114-07-041 M114-07-043 M114-07-042 PF 30 PT Male Straight Thread Male Tapered Thread Clearance External Thread Internal Thread Leave one to two pitch threads uncovered T-Bolt Type Worm Gear Type