Ex1200 7b Ko 590 01 Assembly Manual [PDF]

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KO-590-01



ASSEMBLY PROCEDURE MANUAL



Foreword Assembly work is the final touch that gives the machine life. The quality of a machine's assembly affects its operative performance and service life of the machine. Because a machine's value is determined by its assembly, those who do this work are required to have sufficient know-how about assembly. This manual basically contains assembly know-how such as methods and useful hints for assembling the EX1200-7B Hydraulic Excavator. Please read this manual carefully and try to keep it for reference before you engage in assembly or while you work. This manual is a practical compilation of the following three viewpoints: "the improvement of work safety", "the improvement of efficiency" and "the enhancement of product quality." 1) Safety:



Some hints and information for safe work are provided, such as the weight of the parts, their lifting points when raised with wire ropes and their handling procedures. Work safety is attained with this manual.



2) Quality:



Procedures and hints are described for correct machine assembly. They include the part numbers, tightening torque values of bolts, etc. Correct assembly is essential to provide the machine with a longer service life at maximum performance.



3) Efficiency:



Tool jigs, the facilities necessary to do the work and the preparation needed for each work stage are introduced to assure speedy and effective completion.



We hope this manual will be helpful to you in assembling the machine without a hitch.



i



CONTENTS Pages 1. Precautions······················································································································································ 1



1-1. Safety precautions for servicemen············································································································ 1







1-2. How to use a power wrench···················································································································· 14







1-3. Work precautions···································································································································· 17



2. Workers plan (Backhoe front)························································································································ 29



2-1. Transportation (Backhoe front)················································································································ 30



3. Parts check······················································································································································ 41 3-1. Check······················································································································································ 41 4. Preparations (Backhoe front)························································································································· 42 5. Machines, apparatus, tools, and materials necessary for assembly·························································· 45 6. Assembly of upperstructure··························································································································· 51 6-1. Preparations············································································································································ 51



6-2. Connection of upperstructure and side frames······················································································· 57







6-3. Connection of travel motor hoses············································································································ 67







6-4. Assembly of cab & handrail, step and ladder etc.··················································································· 69







6-5. Installation of counterweight, SCR muffler, camera and rear lamps······················································· 79







6-6. Greasing of swing bearing······················································································································ 95







6-7. Vacuuming (air purge work) & charging of refrigerant············································································· 99







6-8. Final check of superstructure················································································································ 119







6-9. Releasing the air from the main pumps································································································ 123







6-10. Trial operation of superstructure············································································································ 125







6-11. Disassembly procedures for shipment·································································································· 126



7. Mounting procedures for backhoe front····································································································· 131 7-1. Preparation············································································································································ 131



7-2. Mounting of backhoe boom··················································································································· 141







7-3. Mounting of arm···································································································································· 151







7-4. Mounting of bucket································································································································ 161







7-5. Adjustment of track link tension············································································································ 171







7-6. Final trial operation check····················································································································· 173







7-7. Disassembly procedures for shipment·································································································· 174



8. Checks after completing the assembly······································································································· 181 9. Checking machine performance·················································································································· 185



Assembly check sheet·································································································································· 195



ii



iii



Bucket



Arm



Upper roller



Undercarriage



Track spring



Front idler



Track link assembly



Cab



Boom



Front attachment Arm cylinder



Boom cylinder



Bucket cylinder



Final drive



Lower roller



Pump



SCR Exhaust



Counterweight



Radiator



Engine



Upperstructure



Oil cooler



Fuel tank



Urea tank Swing drive



EX1200-7B Backhoe front



iv



Weight: 116 000 kg (255 734 lb) Standard Weight: 118 000 kg (260 143 lb) BE



BACKHOE FRONT



EX1200-7B Assembly Process Chart



1. Precautions 1-1 Safety precautions for servicemen



1



RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.



Fig. 1-1



2



UNDERSTAND SIGNAL WORDS Machine safety signs incorporate signal words DANGER, WARNING and CAUTION - to designate the degree or level of hazard. DANGER indicates an imminently hazardous situation which, if not avoided, will potentially 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. The NOTE describes cautionary remarks, reference, etc. for assembly. DANGER and WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety items in this manual.



Fig. 1-2



To avoid confusing machine protection with personal safety messages, IMPORTANT is used to indicate a situation which, if not avoided, could result in damage to the machine.



1



3



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 Hitachi dealer in the same way as you order other replacement parts (be sure to state the machine model and serial number when ordering.)



Fig. 1-3



Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair its functions and/or safety, and affect machine life. The safety messages in this chapter are intended to illustrate basic safety procedures for hydraulic excavators. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor before operating or performing maintenance work on the machine.



4



DESIGNATE ONE LEADER AND TWO SUBLEADERS In order to work with the greatest safety and ease, designate a foreman and two subleaders as working partners. When assembling the superstructure, station the subleaders at the front and rear of the machine. They should carry out and follow the leader's signals with utmost care to avoid breakage of components and personal injury. Fig. 1-4



5



CLEAN THE MACHINE REGULARLY Remove any grease, oil or dirt build-up to avoid possible injury or machine damage. Do not spray water or steam inside the cab.



Fig. 1-5



2



6



WEAR PROTECTIVE CLOTHING Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Wear close fitting clothing and safety equipment appropriate to the job. You may need: • Hard hat • Safety shoes • Safety glasses, goggles, or a face shield • Heavy gloves • Hearing protection • Reflective clothing • Wet weather gear • Respirator or filter mask.







7



Fig. 1-6



PREPARE FOR EMERGENCIES Be prepared for the eventuality of a fire. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, a hospital, and the fire department near your telephone.



8



Fig. 1-7



PREPARE SUITABLE LIFTING TOOLS Work with this machine involves lifting heavy and bulky items with a crane. Pay attention to the following points: a) Prepare suitable lifting tools. b) To prevent unnecessary mishaps due to broken wire cables, do not use damaged chains or frayed cables, slings, or ropes. Be sure to use a proper protector and patch. c) Before proceeding with the work, agree on specific signals with the crane operator and the designated leader/subleader team. d) Always keep the area directly below any load clear of people during slinging work. e) Service personnel and mechanics must check the weights given in this manual, and apply the proper lifting procedures when removing any components. f) When using hydraulic excavators for lifting operations, be sure to comply with all local regulations.



Fig. 1-8



3



9



ENGINE SAFETY a) No one should be allowed inside the hydraulic excavator while it is being operated or during assembly. b) Keep hands away from moving parts. c) Sound the horn as an alert to those nearby before starting up the engine. d) Start the engine from the operator's seat and never while standing on the ground. e) To avoid injury or possible machine damage, never start the engine by shorting across the starter terminals.



Fig. 1-9



10



SUPPORT RAISED BUCKET Never work under or near a raised bucket. Lower the bucket to the ground or onto secure blocks.



Fig. 1-10



11



SAFETY AT HEIGHT Take adequate measures to avoid falling from high spots during work. Clean any mud or debris from the steps, walkways, or work platforms before work, and use a safety belt during work. 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 handholds. Before getting off, be sure to align the cab parallel with the tracks. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when getting off the machine.



4



Fig. 1-11



12



FUEL SAFETY AND FLAMMABLE MATERIALS a) Never smoke while refueling or handling flammable materials. b) Shut the engine off while refueling. c) Exercise caution when refueling while the engine is still hot. d) Do not clean parts using opened cans of gasoline or diesel fuel. Use good, commercial, nonflammable solvents.



Fig. 1-12



13



PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of the battery. Battery gas can explode. Never check the 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 (60.8°F). Disconnect the negative ground cable before working on the electrical system or making major repairs. Fig. 1-13-1



Fig. 1-13-2



5



14



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 disconnecting hydraulic or other lines. Relieve the pressure by moving the control levers several times. Tighten all connections before pressurizing the hydraulic system.







• Search for leaks with a piece of cardboard, taking care to protect your hands and body from highpressure fluids. Wear a face shield or safety goggles for eye protection.







• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.



Fig. 1-14-2



15



Fig. 1-14-1



Fig. 1-14-3



Fig. 1-14-4



CHECK EQUIPMENT SAFETY a) Use a piece of cardboard or paper to safely check for leaks in all systems, including the following: Hydraulic system Fuel system b) Use the correct testing gauge type when checking the hydraulic pressure. c) Check all protective parts on the machine (shields, guards, pins, etc.). They should be in good condition and securely fastened. d) Inspect electrical wiring for worn or frayed insulation, and install new wiring if damage has occurred.



Fig. 1-15



6



16



PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.



Fig. 1-16



17



FASTEN YOUR SEAT BELT Prior to operating the machine, thoroughly examine the belt, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component in question before operating the machine. Be sure to remain seated with seat belt securely fastened at all times when the machine is in operation.



Fig. 1-17



18



BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes, or open doors and windows to bring enough fresh air into the area.



Fig. 1-18



7



19



PRACTICE SAFE MAINTENANCE Understand service procedures before performing any work. Keep the work area clean and dry. Never lubricate or service the machine while it is moving. Keep hands, feet and clothing away from power-driven parts. Before servicing the machine.







• • • •







• •







• •







•







•



Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle switch off. Run the engine at slow idle speed without load for 3 minutes. Turn the ignition OFF to stop the engines. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the ignition. Attach a "Do Not Operate" tag to the travel speed select/pilot control shut-off lever Set the travel speed select/pilot control shut-off lever to the P position. Allow the engine to cool.



Fig. 1-19-1



If a maintenance procedure must be performed with the engine running, do not leave the machine unattended. If the machine must be raised, maintain a 90 to 110˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work. Never work under a machine raised by the boom. Inspect certain parts periodically, and repair or replace as necessary. Refer to the relevant section of the Operation Manual. Keep all parts in good condition and properly installed. Fix any damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris. Disconnect the battery ground cable (-) before making adjustments to the electrical system or performing welding work on the machine.



8



Boom Arm



90 to 110°



Fig. 1-19-2



20



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 to the travel speed select/pilot control shut-off lever. This tag is available from your authorized dealer.



Fig. 1-20



21



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. Dispose 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 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.



22



Fig. 1-21



PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris - wear goggles or safety glasses. In order to avoid personal injury, keep bystanders away from the working area when striking any object.



Fig. 1-22



9



23



PREVENT AGAINST FLYING PARTS Grease in the track adjuster is under high pressure. Do not attempt to remove a GREASE FITTING or VALVE ASSEMBLY. Be sure to keep your body and face away from any valve, as pieces may fly off. The travel reduction gears are under pressure. So as to avoid injury from flying parts, be sure to keep your body and face away from the AIR RELEASE PLUG. GEAR OIL is hot. Wait for the GEAR OIL to cool, then gradually loosen the AIR RELEASE PLUG to release pressure.



24



PREVENT BURNS Hot spraying fluids: • After operation, the engine coolant is hot and under pressure. Also, hot water or steam is contained in the engine, radiator and heater lines. Prevent 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 position. Allow all pressure to release before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.











Hot fluids and surfaces: • Skin contact with escaping hot water or steam can cause severe burns. Be sure to stop the engine, and let the engine and radiator cool. Once the system has cooled, slowly loosen the radiator cap to release pressure, then remove it. • Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts also become hot. Wait for the oil and components to cool before starting any maintenance or inspection work.











25



Fig. 1-23



Fig. 1-24-1



Fig. 1-24-2



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 them falling. Keep playing children and bystanders away from the storage area.



Fig. 1-25



10



26



DISPOSE OF WASTE PROPERLY Improper waste disposal can threaten the environment 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.



Fig. 1-26



Allowing air conditioning refrigerants to escape into the air can damage the Earth's atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire as to the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your HITACHI dealer.



27



SERVICE THE AIR CONDITIONING SYSTEM SAFELY Refer to the outside of the freon container for proper handling procedures when servicing the air conditioning system. Use a recovery and recycling system to avoid venting freon into the atmosphere. Never let the freon stream make contact with your skin. Severe frost burns will result.



28



HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paint, and adhesives.



Fig. 1-27



11



29



HANDLE POWER WRENCHES CORRECTLY Misuse of power wrenches (part nos. 4289389 and 4298388) may lead to their breakage or personal injury. Please use power wrenches correctly and in accordance with this manual. 1 For your safety, do not enter into the turning circle



of the wrench. After tightening is complete, a torque acting in the opposite direction will be applied to the wrench. Therefore, do not suddenly let go of the handle, but let it gently rotate back in the opposite direction until the torque is zero.



Fig. 1-28



2 Excessive input torque may cause the output end



or reaction lever to break, causing the wrench to fall from the machine. The wrench may also fall if it slips off the reaction member. Secure the wrench so that it cannot drop, especially when working on vertical surfaces.



Fig. 1-29



Fig. 1-30



3 It is sometimes difficult to remove the power



wrench from a nut or bolt after tightening.This is generally due to elastic deformation (elastic force) between the wrench and bolt. Try changing the clutch direction to L to make the wrench easier to remove. Release the torque on the ratchet handle gradually, since a force will be acting in the opposite direction after changing over the clutch. If it is not possible to change the clutch by hand, do not attempt to use force (a hammer, etc.).



Fig. 1-31



• Try turning the wrench handle slightly in the L direction to make the clutch easier to change over. 1



Fig. 1-32



2



12



30



COMMUNICATION 1 When slinging work is performed on heavy loads, a



predetermined hand signalling method should be used for trouble-free communication. 2 In order to facilitate remote teamwork during



assembly, workers should wear headsets for reliable communication.



Fig. 1-33



Fig. 1-34



13



1-2 How to use a power wrench This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench should be preferred over a power wrench, for reasons of safety and overall quality.



1



METHOD OF USE



4. Input direction selection on the ratchet handle. The input direction is set by using the changeover lever on the ratchet handle.



1. Socket selection and mounting. Select the socket which fits most snugly onto the bolt, and mount the socket on the wrench. Secure the socket to the wrench with a 38.1 mm pin or 25.4 mm bolt.



Changeover lever Fig. 1-39



Fig. 1-35



5. Changeover clutch. Select the input direction by setting the changeover clutch as detailed in the figure to right (Fig. 1-40).



Changeover clutch



2. When accurate torque control is required. Set the torque according to the input/output diagram in Fig. 1-49 (page 16). (Output = input x gear ratio x efficiency)



Fig. 1-40 Fig. 1-36 3. Check the positioning of the reaction lever. Depending upon the wrench type the reaction lever usually acts radially. Due to the large reaction force applied to the reaction lever, the reaction lever should be positioned so that it is both secure and stable.



6. Completion of work. On completion of tightening, remove the wrench from the nut or bolt. Elastic deformation (force) between the wrench and bolt can make it difficult to remove the power wrench. In this case, gradually release the torque on the ratchet handle and change over the clutch direction.



2 1



Fig. 1-41



Straight type reaction lever



Fig. 1-37 When using an "L-type" torque wrench, make sure that the distance "L" between the center of the bolt and support point is at least the figures shown below. Failing to observe this minimum distance can damage or break the bolt, or cause the output shaft to become jammed.



Clutch selection L (counter clockwise)



L type reaction lever



Model



L



8-150P



110



8-300P



130



12-450P



145



12-600P



R (clockwise)



160 (Unit: mm)



Fig. 1-38



14



Fig. 1-42



2



THE CORRECT HANDLING OF POWER WRENCHES Misuse of power wrenches (part nos. 4298389 and 4298388) may lead to their breakage or personal injury. Please use power wrenches correctly and in accordance with this manual.



CAUTION: 1. Changing the clutch Base line Yellow



Direction



Red



• Set the base line of the dial to the R or L marker on the power wrench main body. (Select R for clockwise, L for counterclockwise movement.) A tightening torque is applied with R and a loosening torque with L. Note that reverse operation may damage the clutch. • The changeover clutch is intended to prevent reverse rotation when the force is released during a tightening or loosening operation, and is not designed to transmit torque in the manner of the ratchet handle.



Ratchet handle Fig. 1-43



2. Stay away from the ratchet handle turning circle.



For your safety, do not enter into the turning circle of the wrench. After tightening is complete, a torque acting in the opposite direction will be applied to the wrench. Therefore, do not suddenly let go of the handle, but let it gently rotate back in the opposite direction until the torque is zero.



Fig. 1-44



3. Don't drop the wrench. Excessive input torque may cause the output end or reaction lever to break, causing the wrench to become removed from the component. The wrench may also become removed if it slips off the reaction member. Secure the wrench so that it cannot fall, especially when working on vertical surfaces.



Fig. 1-45



Fig. 1-46



4. After tightening. It is sometimes difficult to remove the power wrench from a nut or bolt after tightening.This is generally due to elastic deformation (elastic force) between the wrench and bolt. Try changing the clutch direction to L to make the wrench easier to remove. Release the torque on the ratchet handle gradually since a force will be acting in the opposite direction after changeover of the clutch. If it is not possible to change over the clutch by hand, do not attempt to use force (a hammer, etc.).



Fig. 1-47



1



• Try turning the wrench handle slightly in the L direction to make the clutch easier to change over.



2



Fig. 1-48



15



(2548)



5. Power Wrench Input/Output Diagram Input/Output Diagram



(2254)



[Output=input × gear ratio x efficiency] (1960)



In selecting a power wrench, give due consideration of the differences in power performance between the different wrench types.



Output kgf·m (lbf·ft) (N.m)



(1666) (1372) (1078) (784) (490)



Bolt



Input kgf·m (lbf·ft) (N.m)



Power Wrench



(98) (196) (294) (392) (490) (588) (686) (784) (882)



(6860)



(5880)



(4900)



Fig. 1-49



Output kgf·m (lbf·ft) (N.m)



(3920)



(2940)



(1960)



Input kgf·m (lbf·ft) (N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)



6. Torque Specifications No.



1



Descriptions



ORS fittings for hydraulic hoses and piping



Torque



Bolt Dia (mm)



Wrench Size (mm)



N·m



kgf·m



lbf·ft



7 1— 16 —12 UNF



41



210



21



154



11 1— 16 —12 UNF



50



350



35



258



2



Cab mounting bolt



16



24



210



21



154



3



Side frame mounting bolt



42



65



4000



400



2950



4



Counterweight mounting bolt



45



65



4000



400



2950



5



Front pin lock bolt (Backhoe front) A. Front pin lock bolt B. Stopper bolt



20 20



30 30



400 400



40 40



295 295



Note: *Hexagonal socket wrench



16



1-3 Work precautions



1



APPLYING LUBRICANT 1



Be sure to apply a suitable lubricant to mounting bolts before tightening. Use lubricant made by mixing white zinc jelly and spindle oil in 1: 1 proportions. In the case that these materials are not available, make up the lubricant from materials of the same composition: Material



Composition



White zinc jelly



Composition list given on page 27



Spindle oil



Composition list given on page 27



2



Lubricant should be applied to both the bolt and spacer, in the positions marked in the diagram below. Spacer



Face area



2



White zinc jelly Spindle oil



1:1



Lubricant



Bolt



Face area Thread



Fig. 1-50



Base of the head Fig. 1-51



HANDLING SEALS Remove the seal fitted to the ports and pipes of hydraulic components just before assembly, to prevent the ingress of dust. 2 Oil will come out when removing the seals from the hydraulic ports. Collect it with a suitable oil container. 3 Lightly apply High Tack Adhesive/Sealant #98D to the O-ring before hose connection.



High Tack Adhesive/ Sealant #98D



1



Fig. 1-52



Note: Obtain high tack adhesive/sealant #98D through the manufacturer detailed on page 27.



3



Fig. 1-53



CONNECTING HOSES 1



Be careful not to damage the joining surfaces of the hydraulic components. 2 Make sure that no dust has adhered to the seat faces of the hoses and adaptors. 3 When connecting hoses, do not twist them or their service life will be shortened. 4 When connecting the hoses, avoid contact with other parts.



CAUTION: Hydraulic ports are sealed with plugs on shipment from the factory. On removal of these plugs, hydraulic oil will escape due to the internal hydraulic pressure built up through transportation, etc.



17



4



BATTERY DISCONNECT SWITCH This machine is equipped with a battery disconnect switch b and starter disconnect switch c located behind the cab. The battery ground circuit can be disconnected by turning battery disconnect switch b to OFF position before replacing the battery, checking the electrical system, or performing welding work on the machine. At times such as changing the battery, inspecting or performing maintenance on the electrical system, or when welding on the machine, the battery earth circuit can be cut off by putting battery disconnect switch b in its OFF position. Similarly, the power supply to just the starter motor can be cut off by putting starter disconnect switch c in its OFF position.



Fig. 1-54



IMPORTANT: When battery disconnect switch b is turned OFF just after the key switch is turned OFF, controllers may be damaged. Wait until DLU indicator a turns OFF. Then turn battery disconnect switch b to OFF position.



Note:



ON



a



c



OFF



It takes approximately 5 minutes until DLU indicator a turns OFF.



ON



Battery Box



18



b



OFF



Fig. 1-55



5



TIGHTENING LARGE-DIAMETER BOLTS DURING ASSEMBLY. 1 It is vital that large-diameter bolts be tightened to



the specified tightening torque during assembly. If torque specifications are not followed, the operation of the machine will be affected, with machine failure, lowering of functionality and shortening of machine life potentially resulting. Be careful, therefore, to note the correct tightening torque at each stage of assembly. This manual describes use of a power wrench to achieve the required torque, but a hydraulic wrench will allow for even more accurate and efficient tightening work.



Fig. 1-56



2 Be sure to tighten each bolt to the specified torque



using a torque wrench, power wrench, or hydraulic wrench.



Torque wrench 1) After tightening a bolt to the specified torque, mark the alignment of the bolt head, spacer and bolted part. (See Fig. 1-56.) 2) Use only genuine Hitachi bolts.



Fig. 1-57



CAUTION: i) If a bolt is too long, you will not be able to fully tighten it. ii) If a bolt is too short, you will not be able to be tighten it sufficiently to secure the parts, possibly resulting in a serious accident.



6



Pin Moly coat spray Fig. 1-58



NOTES ON INSERTING PINS WHEN AFFIXING THE FRONT-END ATTACHMENT. 1 When attaching the front-end attachment,



thoroughly clean away the anticorrosive applied to the pins and pin holes before inserting the pins, then regrease them and spray them with Moly coat. 2 Be sure to check the alignment of pin holes when joining parts. Do not use unreasonable force to insert pins, and attempt to insert all pins manually. If this is insufficient, use a medium-sized hammer to ease the pin in place. The use of forklift prongs to force in pins is absolutely forbidden. Any other unreasonable force can lead to a pin being misformed and rendered unusable, and should be avoided. (Fig. 1-59)



7



Pin



Fig. 1-59



APPLYING SEALING TAPE. Wrap sealing tape around the bolt in the opposite direction to the thread direction. Do not cover the first two threads, as indicated in Fig. 1-60.



Fig. 1-60



19



8



PRECAUTIONS FOR CONNECTING THE PILOT HOSES Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants may cause the pilot valve to malfunction.



Plug



Plug







Step 1



The ends of both the valve and hose to be connected will be sealed with plugs. Detail A



Fig. 1-61



Adaptor



Step 2



1) Remove the plugs. 2) Thoroughly clean the hose fitting and adaptor, then connect them, taking care to prevent the ingression of any contaminants.



Fitting Remove the plugs



Detail B Fig. 1-62







Step 3



Adaptor



Connect the adaptor and hose fitting.



Fitting



Notes: i) When connecting hoses, do not twist them, or their service life will be shortened. ii) Connect the hoses so as to avoid contact with other parts. iii) Make sure that no dust has adhered to the seat face of the hoses. iv) Be careful to not damage the joining surfaces of the hoses.



20



Detail C



Fig. 1-63



9



Standards for Hydraulic Joint Work



A



ORS joint Work procedure 1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.



Note: Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts. Check for dirt and scars



Adapter



Hose, union part Fig. 1-64



O-ring



2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand



98D (Loctite, Ltd) to the screw part of the hose union.



Notes:



i) Remember to handle the O-ring with your bare hands. ii) Press the entire O-ring with your fingers and install it properly. iii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.) Handle the O-ring with your bare hands!



Apply spray grease here.



Fig. 1-65



3 Screw the hose and union into the adapter.



Notes: i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the hose horizontal to each other to keep them immobile. ii) Tighten the union nut fully with your hands. iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality, loosen the union nut and make sure to verify the O-ring. Tighten the union nut fully with your hands



Fig. 1-66 4 Tightening the union







• To tighten the union, use a spanner-style torque wrench and control the torque properly. • Use a specified torque wrench.



Note: After the work, carry out a check using a white pen.



21



B



Union joint Work procedure 1 Check that the adapter and hose union seat surfaces are free of scars or dirt.



Note: Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts. Adapter seat surfaces



Hose union seat surface



Fig. 1-67



Fig. 1-68



Apply spray grease here 2



Apply spray grease to the screw parts of the hose and union.



Note: Do not overapply. (When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil leak.) 3



Screw the hose into the adapter.



Note: Tighten fully using your hands. (If there are no scars on the thread, you will be able to screw it fully with your hands.) Tighten the union nut fully with your hands



Fig. 1-69 4 Tightening the union







• To tighten the union, use a spanner-style torque wrench and control the torque properly. • Use a specified torque wrench.



Notes: i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it. ii) After the work, carry out a check using a white pen.



22



C



Split flange joint Work procedure 1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.



Notes: i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts. ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt.



Check for scars and dirt



Fig. 1-70



O-ring



Hose, flange



2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D



(Loctite, Ltd).



Notes: i) Remember to handle the O-ring with your bare hands. ii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.) iii) Press the entire O-ring with your fingers and install it properly.



Handle the O-ring with your bare hands. Do not overapply the bond.



Fig. 1-71



3 Installing the split flange



1) Temporarily install one side of the split flange using the socket bolts.



2) Confirm the O-ring and set the hose onto the split flange.



Note:



Notes:



Using your hands, screw in the bolt to about half its length.



i) Make sure to insert the hose horizontally to the installation surface. ii) Take care so that the O-ring does not fall out of place.



Screw in the bolt to about half its length. Pay attention to the O-ring Fig. 1-72



Split flange



Fig. 1-73



Socket bolts



23



3) After setting the hose, install the other split flange.



Notes: i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-ring may fall off. ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.



Install other split flange



Fig. 1-74



If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase, causing the O-ring to fall off



Fig. 1-75 4 Tightening the socket bolt



1) Temporary tightening, hose angle adjustment • Make sure to tighten the bolts in the correct order to avoid lopsided tightening. • The bolts should be tightened using a crisscross sequence. • The hose should still have movement even after the bolts have been tightened. • Adjust the hose angle. 1



4



3



2



Bolt tightening sequence



2) Tightening the bolts • Tighten the bolts using a crisscross sequence in the same way as for temporary tightening. • Be careful not to tighten the bolts lopsidedly. • Be careful not to overtighten the bolts with an impact wrench. 3) Checking the torque • Use a torque wrench to check that the bolts are properly tightened. • Check the bolts in the same crisscross sequence as for tightening. • After the work, carry out a check using a white pen.



Fig. 1-76



No gap on one side and too much gap on the other side



In the case of lopsided tightening Fig. 1-77



24



Should be tightened so that the gaps are uniform Fig. 1-78



ADJUSTING LIFTING ANGLE Example of usage of a chain block or lever block. By adjusting length “L” on the chain block (or lever block) connecting the wire ropes, the lifted angle of the load can easily be adjusted.



Wire rope



Wire rope



L



L



L'



10



Chain block (Lever block) Chain block



Wire rope Lever block



Fig. 1-79



Work



Example The angle of the workpiece in Fig. 1-80 can be adjusted using chain blocks A .



Workpiece Chain block



A



Chain block



A



a