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
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 INTRODUCTION

ADDITIONAL REFERENCES

Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.

• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance tests, and
troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 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
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.

UNITS USED
SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
2
Example : 24.5 MPa (250 kgf/cm , 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 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 Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm 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 in-
jury.
Follow recommended precautions and safe operating
practices.

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 in-
jury.
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 specific 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.
CAUTION also calls attention to safety messages in this SA-1223

manual.

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 machine.

NOTE indicates an additional explanation for an

element of information.

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

Carefully read and follow all safety signs on the machine

as well as all safety messages in this manual.
Safety signs must be installed, maintained and replaced
if damaged.
If a safety sign or this manual is damaged or missing,
order a replacement from your nearest Hitachi dealer
in the same way you order other replacement parts
(be sure to state machine model and serial number
when ordering).
Allow only properly trained, qualified, authorized per-
sonnel to operate the machine. SA-003

Learn how to correctly operate and service the machine.

Keep your machine in proper working condition.
Always operate the machine within the specification.
Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every possible hazardous situation you may en-
counter. If you have any questions concerning safety,
you should first consult your supervisor and/or your
nearest Hitachi dealer before operating or performing
maintenance work on the machine.

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 and 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 any fire or accidents which may occur. SA-437

Keep emergency numbers for doctors, ambulance

service, hospitals, and fire department posted near
your telephone.

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

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 oper-

ating the machine.

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 uncomfortably loud noises.

SA-434

INSPECT MACHINE DAILY

If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435

SA-3
 SAFETY
TIDY UP INSIDE CAB

Always keep inside the cab clean by observing instruc-

tions below, to prevent any personal accidents from oc-
curring.
Remove mud and/or oily material from the shoe soles
before entering the cab. If pedals are operated without
removing mud or oily matter, the foot may slip off the
pedal, possibly creating a hazardous situation.
Do not leave parts and/or tools around the operator’s
seat.
Do not keep a transparent water bottle in the cab. The
transparent water bottle may concentrate the sun light
like a lens, possibly causing a fire.
Do not wear radio or music headphones and do not use
a cell phone while traveling or operating the machine.
Never allow hazardous materials such as combustible
and/or explosive material in the cab.
Do not leave a lighter in the cab. If the temperature in the
cab increases, the lighter may explode.

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.
Maintain a three-point contact with the steps and
handrails.
Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms, SA-439

thoroughly remove such material.

SA-4
 SAFETY
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
mis-operation of the machine.

The seat should be adjusted whenever the operator

for the machine changes.
The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back firmly against the seat back.
If not, readjust the seat forward or backward, and
check again. SA-378

FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may be-
come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

Be sure to remain seated with the seat belt securely

fastened whenever operating the machine.
Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at
least once every 3 years regardless of appearance SA-237

SA-5
 SAFETY
MOVE AND OPERATE MACHINE SAFELY

Always be aware that there is a potential danger around

the machine while operating the machine.

Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped).
Before starting to move or operate the machine, sound
the travel alarm and horn to alert bystanders.
Use a signal person when moving, swinging, or oper- SA-1291

ating the machine in congested areas. Locate the

signal person so that the operator can always witness
the signal person.
Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
Never allow any persons or obstacles to enter the
machine operation areas.
Use appropriate illuminations.

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 tracks
or on ground.
Do not start engine by shorting across starter termi-
nals. A hazardous situation may be created and/or
possible damage to the machine may result. SA-444

Before starting the engine, confirm that all control lev-

ers are in neutral.

JUMP STARTING

Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE EN-
GINE” chapter.
The operator must be seated 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 SA-032

could result in a battery explosion or a runaway ma-

chine.

KEEP RIDERS OFF MACHINE

Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the
machine.

Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
Only allow the operator is allowed on the machine.
Keep riders off.

SA-1292

SA-7
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND

When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.

Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling 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 excavations and road shoulders.
When working on an incline or on a road shoulder, SA-1293

employ a signal person as required.

Never allow bystanders to enter the working area such
as swing radius or traveling range.
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 may become
loose and slippery.
When operating the machine near open flame, sparks,
and/or dead grass, a fire may easily break out. Use
special care not to cause a fire.

SA-8
 SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.

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 direc-
tions.

SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN
Incorrect travel pedal/lever operation may result in seri-
ous 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 towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.

SA-1294

SA-9
 SAFETY
DRIVE MACHINE SAFELY

Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to
property.

Before moving the machine, confirm which way to A

move travel pedals/levers for the corresponding di-
rection you wish to travel.

Avoid passing over any obstructions. Failure to do so

may cause soil, rock fragments and/or metal pieces to
be scatter around the machine. Keep bystanders away SA-1295

from the machine.

Traveling on a grade may cause the machine to slip or to
overturn, possibly resulting in serious injury or death.

When traveling up or down a grade, keep the bucket in

the direction of travel, approximately 200 to 300 mm (8
to 12 in) (A) above the ground so that lowering the
bucket onto the ground can quickly stop the machine.
If machine starts to skid or becomes unstable, lower
the bucket immediately.

Traveling across the face of slope or steering on a A

slope may cause the machine to skid or to turnover. If SA-1296

the direction must be changed on a slope, first move

the machine to level ground, then, change the travel-
ing direction to ensure safe operation.

SA-441

SA-442

SA-10
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

Park the machine in compliance with the safe parking

procedures described on page S-15 to prevent the
machine from running away.

• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park
on a grade.
• Park a reasonable distance from other machines.

SA-1297

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). SA-383
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 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. SA-384

• 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
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494-8

SA-12
 SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA

If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
• Make sure that no personnel other than the signal
person or no obstacles are present in the working area
before operating the machine.

SA-667

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.

• Never allow the bucket to pass over anyone to avoid

personal injury or death.

SA-668

AVOID UNDERCUTTING

In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.

SA-1300

SA-13
 SAFETY
AVOID TIPPING

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
machine.
• 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.
SA-1301
• 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-E01A-0540-4

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur

causing serious injury or death.

SA-1302

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 SA-672

area, and/or the utility companies directly.

Have them mark all underground utilities.

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.

SA-673

AVOID POWER LINES

Serious injury or death can result if the machine or front

attachments 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 (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any SA-1305

person on it to be affected by electric shock. Keep all

bystanders or co-workers away from the site.

SA-15
 SAFETY
DO NOT USE FOR CRANING OPERATIONS

NEVER use the machine for craning operations. If the

machine is used for craning operations, the machine
may tip over and/or lifted load may fall, possibly resulting
in serious injury or death.
This machine has been exclusively designed to engage
in excavation and loading works.
This machine is not equipped with any of the necessary
safety devices that could allow the machine to be used
for craning operation.

SA-014

PROTECT AGAINST FLYING DEBRIS

If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious
injury may result.

• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris
exist, or when removing or installing pins using a
hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432

SA-16
 SAFETY
PARK MACHINE SAFELY

Unless the machine is not correctly parked, any

hazardous situations such as running away of the
machine or damage by vandalism may result, causing
the machine to operate unsafely when the engine is
re-started. Follow instructions described below when
parking the machine.

• Park the machine on solid level surface to prevent the

machine from running away.
• Lower the bucket and/or blade to the ground.
SA-1306

• Pull the lock lever to the LOCK position.

• Turn the auto-idle switch (optional) OFF. Failure to do
so may create a hazarduos condition as the engine
speed may unexpectedly increase.
• 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.
• Before leaving the machine, close all 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
spontaneously.

SA-019

SA-17
 SAFETY
SAFETY TRANSPORTING

The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.
SA-1307
• Provide an appropriate truck or trailer for transporting
the machine.
• Be sure to have a signal person.
• Take the following precautions when loading/unloading
the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient
of less than 15 degrees.
5. Be sure to turn the auto-idle switch (13) OFF. 13
6. Slowly drive the machine.
7. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
8. The top end of the ramp where it meets the flatbed is M1M7-01-028

a sudden bump. Take care when traveling over it.

9. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
10. Do not operate any levers besides the travel levers
when driving up or down the ramp.
11. Prevent possible injury from machine tipping while the
upperstructure is rotating.
12. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.

Refer to "transporting" chapter in operator’s manual for

details

SA-18
 SAFETY
PRACTICE SAFE MAINTENANCE

Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body
to a moving, high pressure, and/or high temperature part
of the machine. To avoid serious personal injury or death,
follow the instructions described below.
• Thoroughly coordinate the working procedures to be
taken hereafter with the co-workers before beginning
work such as inspecting/servicing the machine, or
replacing the attachiment .
• Safely park the machine in accordance with the
instructions for “Park Machine Safely.”
• Keep the work area clean and orderly.
• Attach a “DO NOT OPERATE” tag in an easy-to-see
SA-028
location such as on a door or a control lever.
• If moisture permeates into the electrical system,
malfunction and/or erroneous movement of the
machine may result. Do not clean sensors, cable
connectors, and the cab inside using water and/or
steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed 90 to 110
with the engine runnning, be sure to appoint an
overseer.
• Never lubricate or service the machine while moving it.
• Repair the cracked windowpane before servicing the M1M7-04-006

machine. Failure to do so may cause personal injury.

• Whe raising the machine above the ground using the
front attachment function, maintain the angle between
the boom and the arm in the range of 90 to 110 .
Never allow anyone to enter under the machine raised
with the front attachment function.
• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed.
• Always use the specified tools correctly.
• Always use a clean tool. SA-527

• Fix any damage found immediately. Replace worn or

broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.

SA-19
 SAFETY
• Disconnect battery ground cable ( ) before making
adjustments to electrical systems or before welding on
the machine.
• 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 in an easy-to-see place such as
on the cab door or control lever.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to hold
the engine start key during inspection/service work.
SA-287

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 with stays
or blocks strong enough to support the machine
and/or attachment weight.

SA-527

STAY CLEAR OF MOVING PARTS

Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• 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.

SA-026

SA-20
 SAFETY
PREVENT PARTS FROM FLYING

Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTINGS or

VALVE ASSEMBLIES.
• As pieces of parts may fly off, be sure to keep body
and face away from the valve.

Travel reduction gears are under pressure.

SA-344

• As pieces of parts 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 the air release plug to release
pressure.

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 accidents.
• Keep children and bystanders away from storage
areas.

SA-034

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 prevent possible injury from hot spraying water,

stop the engine. Begine to work after the engine and
radiator are sufficiently cooled
• DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop. SA-039

Allow all pressure to be release before removing the

cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure by slowly removing the cap.

Hot fluids and surfaces:

Engine oil, gear oil and hydraulic oil also becomes 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

SA-22
 SAFETY
REPLACE RUBBER HOSES PERIODICALLY

Rubber hoses that contain flammable fluids such as

hydraulic oil or fuel 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 visual inspection alone.

• Periodically replace the rubber hoses. (Refer to the

“Periodical Replacement Parts” section 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 SA-019

on a person nearby, which may result in severe burns,

gangrene, or otherwise serious injury or death.

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. Make sure that
all connectors are completely connected before
applying pressure.
SA-031
• 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 must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-23
 SAFETY
PREVENT FIRES

Check for Oil Leaks:

Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.

• Check for 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, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts. SA-019

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes or hoses.

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.

SA-24
 SAFETY
Precautions for Handling 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.
• Don’t store flammable fluid near open flames.
• Don’t burn or crush a pressurerized container.
• Don’t store oily cloths. They are liable to catch fire.
• Don’t wind easy-to-absorb-oil asbestos or glass wool
around high-temperature parts such as a muffler or
exhaust pipe.

Check Heat Shield Covers around Engine

Compartment
If the engine compartment heat shield cover becomes
broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the
machine.

Check Key Switch:

If fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.

• Always check key switch function before operating the

machine 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 hasstopped.
If any abnormalities are found, be sure to repair
them before operating the machine.

SA-25
 SAFETY
EVACUATING IN CASE OF FIRE

If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.
• 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 to the explanation pages on the “Emergency

Evacuation Method” in the operator’s manual.

SS-1510

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate the machine 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 outside air into the
area.

SA-016

SA-26
 SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and

prepared 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 a fire hazard. Store
flammable objects in a safe place before starting grind-
ing.

After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

Flammable spray can be generated by heating near

pressurized 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, SA-030

etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.

SA-27
 SAFETY
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.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Allow fumes to disperse at least 15 minutes after
welding or heating. SA-029

• Use attention to the following points when removing

paint.
1. If you sand or grind paint, avoid breathing the dust
which is created.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding.
3. Remove solvent or paint stripper containers and
other flammable material from area.

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 the
electrolyte level is lower than specified. Explosion of
the battery may result. SA-032

• When a terminal become loose, it may induce sparks.

Securely tighten all terminals.

Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness. If electrolyte is splashed
into eyes, flush your eyes continuosly with water for
about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-28
 SAFETY
PRECAUTIONS FOR HANDLING REFRIG-
ERANT

If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

container for handling refrigerant.
• Use a recovery and recycling system to avoid venting
refrigerant into the atmosphere.
• Never allow the skin to directly come in contact with
refrigerant.
SA-405

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,
electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct
procedures and use recommended equipment. SA-309

• See your nearest Hitachi dealer for MSDS.

SA-29
 SAFETY SIGNS
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste 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.

• When draining fluid, use a leakproof container with a

capacity larger than the drained fluid volume to
receive it.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Inquire on the proper way to dispose of harmful waste SA-226
such as oil, fuel, coolant, brake fluid, filters, and
batteries from your local environmental or recycling
center.

BEFORE RETURNING THE MACHINE TO THE

CUSTOMER

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

SA-435

S517-E01A-0435

SA-30
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL Group 5 Floor-Tilting Device
SECTION 2 UPPERSTRUCTURE
Group 1 Canopy
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Solenoid Valve
Group 8 Revolution Sensing Valve
Group 9 Auxiliary Flow Selector Valve
(Optional)
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
TECHNICAL MANUAL
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Revolution Sensing Valve
Group 3 Swing Device
Group 4 Control Valve
Group 5 Pilot Valve
Group 6 Travel Device
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Troubleshooting A
Group 3 Troubleshooting B
Group 4 Troubleshooting C
Group 5 Electrical System Inspection
 SECTION 1
GENERAL INFORMATION

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology ........ W1-1-7

Group 2 Tightening
Tightening Torque Specifications .............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
Periodic Replacement of Parts ............. W1-2-10

Group 3 Painting
Painting .................................................. W1-3-1

Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank ........... W1-4-1

Group 5 Floor-Tilting Device

Floor-Tilting Device Operetion
Procedure............................................. W1-5-1
Procedure for Floor Tilting up ................. W1-5-2
Procedure for Floor Tilting down ............. W1-5-4

1M9W-1-1
(Blank)

1M9W-1-2
 GENERAL / Precautions for Disassembling and Assembling
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.
W1-1-1
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.
 GENERAL / Precautions for Disassembling and Assembling
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.
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 instal-
lation of the pump, swing motor, travel motor or cyl-
inder 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
motor 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.
 GENERAL / Precautions for Disassembling and Assembling
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 hydrau-
lic oil level.
M1M7-05-024
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A

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.
B W105-03-05-019
(2) Check the slide surface 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

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air.

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it W105-03-05-020

is installed correctly on the seal ring. Correct D Incorrect

a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.

b b

a=b a b

W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
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 W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
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 W105-04-01-008
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.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
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. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Scoring Separation of W162-01-01-006

Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
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 “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia. Wrench Size Torque

No. Descriptions Q’ty
mm mm Nm (kgf m) (lbf ft)
1. Engine cushion rubber mounting bolt 12 4 19 88 (9) (65)
2. Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
3. Hydraulic oil tank mounting bolt 12 4 19 88 (9) (65)
4. Fuel tank mounting nut 10 3 17 20 (2) (15)
7/16-20UNF 17 24.5 (2.5) (18)
19 29.5 (3) (22)
Metal face seal 9/16-18UNF
22 39 (4) (29)
Union joints fitting for hydraulic
3/4-16UNF 27 93 (9.5) (69)
for hydraulic hoses and piping
5. 1-1/16-12UNF 36 175 (18) (129)
hoses and
pipes 1-5/16-12UNF 41 205 (21) (151)
9/16 UNF 19 44 (4.5) (32)
ORS 11/16 UNF 22 74 (7.5) (55)
13/16 UNF 27 103 (10.5) (76)
6. Pump mounting bolt 12 2 10 (Socket) 88 (9) (65)
7. Pump cover mounting bolt 10 8 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
8.
Control valve base mounting bolt 10 4 17 49 (5) (36)
9. Swing device mounting bolt 16 8 24 205 (21) (101)
10. Battery mounting nut 6 2 10 5 (0.5) (3.5)
12 5 19 88 (9) (65)
11. Canopy mounting bolt
10 5 17 49 (5) (36)
12 5 19 88 (9) (65)
12. Cab mounting bolt
10 5 17 49 (5) (36)
Swing bearing Upperstructure 12 27 19 108 (11) (80)
13.
mounting bolt Undercarriage 12 24 19 108 (11) (80)
14. Travel device mounting bolt 14 24 22 175 (18) (130)
15. Sprocket mounting bolt 14 24 22 175 (18) (130)
16. Upper roller mounting bolt 16 2 24 231 (23.5) (170)
17. Lower roller mounting bolt 14 16 22 177 (18) (130)
6 10 5 (0.5) (3.5)
18. Cover mounting bolt 8 13 9.8 (1) (7)
10 17 49 (5) (36)
19. Counterweight mounting bolt 24 3 36 930 (95) (398)
10 17 49 (5) (36)
12 19 88 (9) (65)
20. Front pin lock plate bolts 14 22 137 (14) (101)
16 24 205 (21) (152)
18 27 390 (40) (290)
21. Side-cutter mounting bolts 14 6 22 175 (18) (130)
22 Track roller guard mounting bolt 16 12 24 265 (27) (196)

NOTE: (1) Apply lubricant (i.e. white zinc B

dissolved into spindle oil) to reduce
their friction coefficients.
(2) Remove rust, dirt, and dust before
installing fasteners.

W1-2-1
 GENERAL INFORMATION / Tightening
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
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. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or
components.

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
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)

W1-2-2
 GENERAL INFORMATION / Tightening
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
lubricant.
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 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.

Tighten from center and diagonally

Equally tighten upper and lower Tighten

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-3
 GENERAL INFORMATION / Tightening
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. W105-01-01-015

2. Be sure to use only specified WRONG

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 W105-01-01-016
the port. Hand-tighten bolts to
hold 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 W105-01-01-008

tightening of one bolt fully before RIGHT WRONG

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

RIGHT RIGHT WRONG
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 Bend along edge sharply
tightening, not while loosening. W105-01-01-009

RIGHT RIGHT WRONG

Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

Loosen WRONG
RIGHT

Tighten

W105-01-01-010

W1-2-4
 GENERAL INFORMATION / Tightening
PIPING JOINT

IMPORTANT: 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.

Union Joint 1 4 3 5 2

Metal sealing surfaces (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 nut (3).

M202-07-051
Excessive force will be applied to Joint Body
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten nut (3) to 37
specifications.
30
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them Male Union Joint Female Union Joint
when connecting/disconnecting.
W105-01-01-017

Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N m (kgf m, lbf ft)
30 male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 64 (6.5,47)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37 female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 64 (6.5,47)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37 male coupling without union is similar
to tightening torque of 37 female.

W1-2-5
 GENERAL INFORMATION / Tightening
Piping Joint

Pipe Joint (Metal Joint) 1 4 5 3 2

(Union Nut Wrench size 17 mm)

Metal sealing surfaces (3) (Metal) of pipe (2) and

adapter (1) seal pressure oil.

Take care not damage sealing surfaces when

connecting / disconnecting pipe. M1M7-07-005

Tightening Torque Chart

Wrench Size (mm) 17
Nm 39
Tightening
(kgf m) (4.0)
Torque
(lbf ft) (29)

7 6 9
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.
Hose Fittings
2. Before tightening nut (9), confirm 8 10 M104-07-033
that O-ring (6) is seated correctly
in O-ring groove (8). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting Wrench Size Wrench Size Tightening Torque
in oil leakage. mm mm
3. Take care not to damage O-ring Union Nut Hose Fittings N m (kgf m, lbf ft)
groove (8) or sealing surface
19 17 29.5 (3.0,22)
(10).
22 19 69 (7.0,51)
Damage to O-ring (6) will cause
27 22 93 (9.5,69)
oil leakage.
32 27 137 (14,101)
4. If nut (9) is loose and oil is
36 30,32 175 (18,129)
leaking, do not re-tighten nut (9).
41 36 205 (21,151)
Replace O-ring (6) with a new
46 41 205 (21,151)
one and check that O-ring (6) is
correctly seated in place, tighten
nut (9).

W1-2-6
 GENERAL INFORMATION / Tightening
Quick Coupler

1. Connection Procedure
3 1
• While pulling and fully turning socket ring (1)
counterclockwise, insert socket ring (1) onto plug
(3) until the end face of socket ring (1) comes in
contact with plug (3).
• Release socket ring (1). Check that socket ring
(1) is slightly move backward by the spring force
and the coupler is held in position with balls (2). M1M7-07-006
Be sure to check that socket ring (1) has been 2
moved back fully to the right original position.

2. Disconnection Procedure

• While pulling and fully turning socket ring (1)

counterclockwise, disconnect the coupler. As no
check valve is provided in the coupler, take care
that oil may flow out of the coupler when the
coupler is disconnected.
• After the coupler is disconnected, plug the holes
with the exclusively prepared plugs.

CAUTION: Take care not to damage the joint

surfaces when disconnecting or connecting
the coupler.

Before disconnecting or connecting the

coupler, clean the coupler and its
surroundings with a cleaning solvent and
completely wipe off the cleaning solvent. Use
extra care not to allow foreign matter such as
dirt to enter the coupler.

Disconnect or connect the coupler in the

correct procedure. Sufficiently check that no
oil leak is present after connecting the
coupler.

After connecting the coupler, check that that

socket ring (1) has been moved back fully to
the right original position.

W1-2-7
 GENERAL INFORMATION / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
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 Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm 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)
Seal Tape Application
Internal Thread
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 External Thread
Clearance
clearances. Do not overwrap.

Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

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

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N m (0.45 kgf m, 3.25 lbf ft)
T-Bolt Type Worm Gear Type
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)

M114-07-043 M114-07-042

W1-2-8
 GENERAL INFORMATION / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the
machine.
W105-01-01-011
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose RIGHT
WRONG
rupture or separation of fitting. Utilize Print
Rubbing Against
marks on hoses when installing to prevent Each Other
hose from being kinked.

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
W105-01-01-012
from rubbing against each other.
WRONG RIGHT
Take care so that hoses do not come into Clamp Clamp
contact with moving parts or sharp objects.

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
 GENERAL INFORMATION / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire
hazards. It is very difficult to gauge the extent of
deterioration, fatigue, or weakening of the parts listed
below simply by visual inspection alone. For this
reason, replace these parts at the intervals shown in
the table below. However, if any of these parts are
found to be defective, replace before starting
operation, regardless of the interval.
Also, when replacing hoses, check the clamps for
deformation, cracks, or other deterioration, and
replace if necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct
replacement.

Periodic Replacement Parts Replacement Interval

Fuel hose (Fuel tank to filter) Every 2 years or 4000 hours
Fuel hose (Fuel tank to injection pump) Every 2 years or 4000 hours
Heater hose (Heater to engine) Every 2 years or 4000 hours
Engine
Engine rubber vibration insulator Every 5 years or 5000 hours
Floor mount rubber Every 5 years or 5000 hours
Pump coupling Every 5 years or 5000 hours
Pump suction hose Every 2 years or 4000 hours
Pump delivery hose Every 2 years or 4000 hours
Base Machine Swing hose Every 2 years or 4000 hours
Auxiliary hose Every 2 years or 4000 hours
Hydraulic
Oil cooler hose (C/V to oil cooler) Every 2 years or 4000 hours
System
Boom cylinder line hose Every 2 years or 4000 hours
Arm cylinder line hose Every 2 years or 4000 hours
Front Attachment
Bucket cylinder line hose Every 2 years or 4000 hours
Pilot hose Every 2 years or 4000 hours

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-10
 GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Color
Upperstructure Outer cover (Right, Left, Rear and Top) YR1-01 [TAXI yellow]
Skirt (Front, Right and Left) SP-424 [Dark gray]
Main frame SP-424 [Dark gray]
Inside (Oil, Fuel tank) SP-424 [Dark gray]
Canopy (Pole) SP-424 [Dark gray]
Stay ( Left) Black
Lever (Travel, Blade) N-10 [N1.0]
Pedal (Travel, Boom swing) SP-424 [Dark gray]
Floor plate, Seat base SP-424 [Dark gray]
Console (Right, Left) SP-424 [Dark gray]
Counterweight SP-424 [Dark gray]
Undercarriage Track frame (Including idler, upper and SP-424 [Dark gray]
lower roller)
Swing bearing Black
Blade (Including cylinder) SP-424 [Dark gray]
Front attachment Boom, Arm, Bucket and Link YR1-01 [TAXI yellow]
(Including cylinder)
Swing post (Including cylinder) SP-424 [Dark gray]

Dark Gray

Cab Type
Dark Gray

Black
TAXI Yellow
Dark Gray

Dark Gray
Dark
Gray

W1M9-01-03-001

Black TAXI Yellow Dark Gray Dark Gray TAXI Yellow

W1-3-1
 GENERAL / Painting
(Blank)

W1-3-2
 GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.

Preparation

1. Park the machine on a solid, level surface. Lower

the front attachment onto the ground.

2. Stop the engine. Loosen cap (1) on hydraulic oil

tank (2) and release any remaining pressure. M1M7-05-024

3. Remove cap (1) on hydraulic oil tank (2). 1

2
4. Install a vacuum pump to the hole without cap (1).
Operate the vacuum pump and maintain negative
pressure in the hydraulic oil tank.
Run the vacuum pump continuously while
working.
W1M9-01-04-001

Vacuum Pump

Hose

Adapter

W1M9-01-04-002

W1-4-1
 GENERAL / Bleeding Air
(Blank)

W1-4-2
 GENERAL / Floor-Tilting Device
FLOOR-TILTING DEVICE OPERATION
PROCEDURE

Preparation
• Park the machine in a flat and solid place.
• Lower the blade.
• Roll-in the arm and bucket, and put them on the
front wooden block or something.

CAUTION: Be careful because interference

of the boom and canopy (cab) takes place
unless the front end attachment is lowered in
advance.
M1M7-07-060

• Close the door of the cab (optional).

W1-5-1
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING UP

CAUTION: If tilting up operation is made with 1

the door open, it interferes with the cover (3).

1. Remove two bolts (2), and remove (3) from the

canopy or cab (1).
: 17 mm
2

IMPORTANT: Near bolts (4), two bolts for fixing the 3

canopy or cab (1) are fitted. Never
4 M1M7-07-061
remove these two bolts in tilting up 4-Pillar Canopy
operation.
A bolt never to be removed can be
identified by the attached cap or red 1
paint.

2. Remove three bolts (4) from the canopy or cab

(1).
: 19 mm

Not to be
removed 4 M1M7-07-063

2-Pillar Canopy

Not to be M1M7-07-062

Cab removed 4

M1M7-07-064

Not to be
removed

W1-5-2
 GENERAL / Floor-Tilting Device
IMPORTANT: The operating torque of adjuster
screw (5) is 24.5 N m (2.5 kgf m) or
lower. In case larger torque is
required, it is probable that bolts (4)
remain unremoved. Re-check from
this perspective.

3. Turn adjuster screw (5). Tilt the canopy or cab (1)

assembly toward front.
5
: 17 mm

4. Turn adjuster screw (5) clockwise until disc (6) on

the side face of the tilting device moves to the
farthest end. M1M7-07-065

2-Pillar / 4-Pillar Canopy

M1M7-07-066

CAUTION: Do not tilt up cab (1) as far as the Cab

striped region. If done so, cab (1) tilts forward
because the center of gravity overhangs the
balancing point, which is dangerous.

5. In cab (1) version machines, stop tilting up 50 mm

before the farthest end [before the striped region
6
(6)].

50 mm

W1M9-01-05-001

IMPORTANT: Do not make tilting up operation by

other means (e.g. by crane) than the
Support
tilting device. The tilting device or
floor could be damaged otherwise.
6. In case of work done lying under the floor, put a
support at the opening space of the raised floor for
security.

M1M7-07-067

W1-5-3
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING DOWN

CAUTION: Do not lower the floor abruptly. If

adjuster screw (5) is rotated abruptly in
lowering the floor, the floor trembles
enormously, which is dangerous.

1. Slowly turn adjuster screw (5) anticlockwise.

8
: 17 mm
9
2. Turn adjuster screw (5) counterclockwise until the
farthest end contacts receiver seat (7). 7

CAUTION: After the floor has been lowered 5 M1M7-07-068

completely, if adjuster screw (5) is kept
turned, it will not be turned any longer when 10 11
unscrewed by about 15 mm because washer
(10) touches pin (11). Be careful not to turn
adjuster screw (5) further because washer
(10) deforms and gets damaged, causing fall
of bolt (12).
12
3. When the floor has been lowered completely,
adjuster screw (5) is drawn. Make adjustment so
that the clearance between collar (8) of adjuster
screw (5) and contact face (9) becomes 2 to 5
mm. W1M9-01-05-002

W1-5-4
 GENERAL / Floor-Tilting Device
4. Install the canopy or cab (1) with three bolts (4). 2-Pillar Canopy
4
: 19 mm
: 90 N m (9.2 kgf m)

M1M7-07-063

4
4-Pillar Canopy

M1M7-07-062

Cab 4

M1M7-07-064

W1-5-5
 GENERAL / Floor-Tilting Device
(Blank)

W1-5-6
 MEMO

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UPPERSTRUCTURE
CONTENTS
Group 1 Canopy
Remove and Install Canopy.................... W2-1-1
Group 2 Counterweight
Remove and Install Counterweight ......... W2-2-1
Group 3 Pump Device
Remove and Install Pump Device ........... W2-3-1
Disassemble Pump Device ................... W2-3-4
Assemble Pump Device ......................... W2-3-6
Maintenance Standard.......................... W2-3-10
Group 4 Control Valve
Remove and Install Control Valve ........... W2-4-1
Disassemble And Assemble
Control Valve ...................................... W2-4-6
Remove and Install Relief Valve
and Make-up Valve ........................... W2-4-12
Disassemble and Assemble Body ....... W2-4-14
Disassemble Unload Section ................ W2-4-16
Assemble Unload Section..................... W2-4-18
Disassemble and Assemble Spool ........ W2-4-20
Disassemble and Assemble
Boom Anti-Drift Valve ........................ W2-4-22
Disassemble and Assemble Shuttle Valve and
Pressure Compensation Valve .......... W2-4-24
Group 5 Swing Device
Remove and Install Swing Device........... W2-5-1
Disassemble Swing Device .................... W2-5-6
Assemble Swing Device ......................... W2-5-8
Disassemble Swing Motor .................... W2-5-14
Assemble Swing Motor ......................... W2-5-16
Maintenance Standards ........................ W2-5-20
1M9W-2-1
SECTION 2
Group 6 Pilot Valve
Remove and Install Front Pilot Valve ...... W2-6-1
Remove and Install Travel Pilot Valve ..... W2-6-3
Remove and Install Blade Pilot Valve...... W2-6-7
Remove and Install
Boom Swing Pilot Valve ...................... W2-6-9
Disassemble Front Pilot Valve .............. W2-6-12
Assemble Front Pilot Valve ................... W2-6-16
Disassemble Travel Pilot Valve ............. W2-6-20
Assemble Travel Pilot Valve ................. W2-6-24
Disassemble Pilot Valves for Boom Swing,
Blade and Auxiliary............................ W2-6-30
Assemble Pilot Valves for Boom Swing,
Blade and Auxiliary............................ W2-6-32
Group 7 Solenoid Valve
Remove and Install
2-Unit Solenoid Valve .......................... W2-7-1
Disassemble 2-Unit Solenoid Valve ........ W2-7-6
Assemble 2-Unit Solenoid Valve ............. W2-7-8
Remove and Install
1-Unit Solenoid Valve ........................ W2-7-10
Structure of 1-Unit Solenoid Valve ...... W2-7-12
Group 8 Revolution Sensing Valve
Remove and Install
Revolution Sensing Valve.................... W2-8-1
Disassemble Revolution Sensing Valve .. W2-8-4
Assemble Revolution Sensing Valve ....... W2-8-6
Group 9 Auxiliry Flow Selector Valve
(Optional)
Remove and Install
Auxiliary Flow Selector Valve .............. W2-9-1
Disassemble Auxiliary
Flow Selector Valve............................. W2-9-4
Assemble Auxiliary
Flow Selector Valve............................. W2-9-6
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