Hitachi EX 8000-6, Workshop Manual

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Page 2: ...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 signa...

Page 3: ...chi Failure to do so may deteriorate the safety function and or service life of the machine In addition personal accident ma chine trouble and or damage to material caused by using unauthorized attachments and or optional parts or equipment will void Hitachi Warranty Policy The safety messages in this SAFETY chapter are in tended to illustrate basic safety procedures of machines However it is impo...

Page 4: ...erating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine 005 E01A 0438 SA 438 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 006 E01A 0434 SA...

Page 5: ...Store them in their specified locations Avoid storing transparent bottles in the cab Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight possi bly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flammable objects and or explosives away from the machine ...

Page 6: ...p 10 Block Valve with Folding Stairway Group 11 Compressor Drive Motor Group 12 Air Conditioner Group 13 Lift Cylinder Group 14 Arm Extend Priority Valve SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Travel Brake Valve Group 4 Drive Tumbler Group 5 Center Joint Group 6 Adjuster Cylinder Group 7 Front Idler Group 8 Upper and Lower Roller Group 9 Track Group 10 Accumula...

Page 7: ...ing Device Group 3 Control Valve Group 4 Control Equipment Group 5 DQR Valve Group 6 Travel Device Group 7 Others Upperstructure Group 8 Others Undercarriage TECHNICAL MANUAL Troubleshooting SECTION 4 OPERATIONAL PER FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Co...

Page 8: ...s for Disassembling and Assembling W1 1 1 Maintenance Standard Terminology W1 1 7 Group 2 Tightening Tightening Torque Specification W1 2 1 Torque Chart W1 2 3 Piping Joint W1 2 6 Periodic Replacement of Parts W1 2 10 Group 3 Bleed Air from Hydraulic Oil Tank Bleed Air from Hydraulic Oil Tank W1 3 1 ...

Page 9: ... condition of lubricants Loose or damaged parts Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work Precautions for Disassembling To prevent dirt from entering cap or plug the removed pipes Before disassembling clean the exterior of the components and place on a work bench Before disassembling drain gear oil from the reduction gea...

Page 10: ...r from Hydraulic System When hydraulic oil is drained the suction filter or the suction lines are replaced or the removal and in stallation of the pump swing motor travel motor or cylinder 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 ...

Page 11: ...r 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 Stop the engine Recheck hydraulic oil level Re pleni...

Page 12: ...re to do the following to prevent trouble 1 Clean the floating seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt After cleaning thoroughly dry parts with compressed air 2 Clean the floating seal and seal mounting bores Check the bore surface for scuffing or scoring by touching the surface with touch 3 Check that the O ring is not twisted and that it is ...

Page 13: ...use slings with the same width and length to keep the lifted load balanced When lifting a load using an eyehole be sure to eliminate any gaps between the sling and load Refer to the right illustration Reduce the load weight so that it is less than 80 of the sling breaking force Avoid using twisted bound connected or hitched slings Do not place any object on twisted or bent slings Refer to the righ...

Page 14: ... the ny lon sling for any damage corresponding to exam ples shown to the right If any damage is found cut and discard the sling Even if no damage is found do not use slings older than 7 years Damaged Appearance W162 01 01 002 W162 01 01 003 W162 01 01 004 W162 01 01 005 W162 01 01 006 W162 01 01 007 W162 01 01 008 Broken Sewing Thread Scuffing Broken Sewing Thread Fuzz Broken Sewing Thread Separat...

Page 15: ...omponents 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 ...

Page 16: ...16 41 1400 140 1030 18 Oil cooler mounting bolt 27 12 41 1400 140 1030 19 Engine bed mounting bolt 42 78 65 5100 510 3760 Swing bearing mounting bolt Upperstructure 56 68 85 9800 980 7230 20 Swing bearing mounting bolt Track 56 94 85 9800 980 7230 Counterweight mounting bolt Main weight 56 20 85 6900 690 5060 21 Counterweight mounting bolt Sub weight 56 8 85 6900 690 5060 Travel device mounting bo...

Page 17: ...AL Tightening W1 2 2 NOTE 1 Apply lubricant e g white zinc B dis solved into spindle oil to bolts and nuts to reduce friction coefficient of them 2 Make sure bolt and nut threads are clean before installing ...

Page 18: ...7 091 Socket Bolt M552 07 090 M552 07 092 Bolt Dia Wrench Size Hexagon Wrench Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M6 10 5 3 3 to 4 2 0 3 to 0 4 2 4 to 3 0 M8 13 6 30 3 0 21 5 20 2 0 14 5 10 1 0 7 2 M10 17 8 65 6 5 47 50 5 0 36 20 2 0 14 5 M12 19 10 110 11 80 90 9 0 65 35 3 5 25 5 M14 22 12 180 18 130 140 14 101 55 5 5 40 M16 24 14 270 27 195 210 21 152 80 8 0 58 M18 27 14 400 4...

Page 19: ...m 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 ap plication 5 Make sure that nut and bolt threads are clean before install ing Remove dirt or corrosion if any Bolt Tightening Order When tightening two or more bolts tighten them al ...

Page 20: ...s alternately and di agonally as shown to ensure even tightening 5 Do not use air wrenches Using an air wrench often causes tight ening of one bolt fully before tightening of the others result ing in damage to O rings or un even tightening of bolts Nut and Bolt Locking Lock Plate IMPORTANT Do not reuse lock plates Do not try to bend the same point twice Cotter Pin IMPORTANT Do not reuse cotter pin...

Page 21: ...ations 2 Scratches or other damage to sealing surfaces 4 or 5 will cause oil leakage at the joint Take care not to damage them when connecting disconnecting M202 07 051 W105 01 01 017 Wrench Size mm Wrench Size mm Tightening Torque Description Union Nut Hose Fittings N m kgf m lbf ft 30 male 17 17 24 5 2 5 18 19 19 29 5 3 0 21 5 22 22 39 4 0 28 5 27 27 93 9 5 69 32 32 137 14 101 36 36 175 18 129 4...

Page 22: ...ulting in oil leakage 3 Take care not to damage O ring groove e or sealing surface 10 Damage to O ring 6 will cause oil leakage 4 If nut 9 is loose and oil is leak ing do not re tighten nut 9 Re place O ring 6 with a new one and check that O ring 6 is cor rectly seated in place tighten nut 9 M104 07 033 Wrench Size mm Wrench Size mm Tightening Torque Union Nut Hose Fittings N m kgf m lbf ft 19 17 ...

Page 23: ...ds 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 T Bolt Type Band Clamp 4 4 N m 0 45 kgf m 3 25 lbf ft Worm Gear Type Band Clamp 5 9 to 6 9 N m 0 6 to 0 7 kg m 4 3 to 5 1 lbf ft W105 01 01 018 Male Tapered Thread Wrench Size mm Tightening Torque N m kgf m lbf ft...

Page 24: ...s hose rupture or separation of fitting Utilize Print marks on hoses when installing to prevent 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 from rubbing against each other Take care so that hoses do not come into contact with moving parts or sharp objects W105 01 01 011 W105 01 01 012 W105 01 ...

Page 25: ... de formation cracks or other deterioration and replace as necessary Be sure to perform periodic inspection of all hoses as shown below and replace or retighten any defective parts found as necessary Consult your authorized dealer for correct replace ment Periodic Replacement Parts Replacement Intervals Fuel hose Fuel tank to filter Every 2 years Fuel hose Fuel tank to injection pump Every 2 years...

Page 26: ... 82 Structure of Pilot Pump W2 3 88 Structure of Pump Transmission Oil Circulation Pump and Air Conditioner Compressor Drive Pump W2 3 90 Group 4 Control Valve Removal and Installation of Control Valve W2 4 1 Disassembly of Control Valve W2 4 7 Assembly of Control Valve W2 4 16 Disassembly and Assembly of Main Relief Valve and Overload Relief Valve W2 4 20 Structure of Make Up Valve W2 4 22 Identi...

Page 27: ...noid Valve 10 W2 10 8 Structure of Solenoid Valve 13 W2 10 9 Structure of Relief Valve 16 W2 10 10 Structure of Slow Return Valve W2 10 11 Group 11 Compressor Drive Motor Removal and Installation of Compressor Drive Motor W2 11 1 Disassembly of Compressor Drive Motor W2 11 4 Assembly of Compressor Drive Motor W2 11 6 Group 12 Air Conditioner Work After Replacing Component W2 12 1 Add Compressor Oi...

Page 28: ...l JISR3211 or equivalent 1 mm 0 03927 in Unit mm W18G 02 01 003 W18G 02 01 001 W18G 02 01 002 W18G 02 01 004 2 5 2 3 4 80 80 1702 1 1734 1 Mark position outside Chamfer corner 4 places Laminated glass Color Transparent Thickness 10 8 mm Chamfer along the Periphery 1 1 ...

Page 29: ...33 1 0 769 1 0 4 R61 4 Tempered glass Color Green Thickness 5 mm Chamfer along the Periphery 777 1 0 514 1 0 4 R61 Tempered glass Color Green Thickness 5 mm Chamfer along the Periphery 1222 6 1 1355 8 1 Mark position NUB34413 50 50 4 R61 2 Tempered glass Color Green Thickness 5 mm Chamfer along the Periphery 478 1 50 324 1 438 2 1 50 Mark position NUB34413 4 R61 5 ...

Page 30: ...nd bolts 5 3 used from right handrails 2 3 19 mm CAUTION Right handrail 2 weight 20 kg 44 lb Right handrail 3 weight 28 kg 62 lb 2 Remove bolts 4 14 used from right handrails 2 3 Remove right handrails 2 3 from right counterweight 1 19 mm 3 Remove the left handrail in the same way as steps 1 to 2 4 Remove bolts 9 12 8 used for each from covers 8 11 2 used for each Remove covers 8 11 2 used for eac...

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