Hitachi EX550-5, Workshop Manual

Page 1: ...EX550 5 EX600H 5 Workshop Manual ...

Page 2: ...NTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling W1 1 1 Maintenance Standard Terminology W1 1 4 Group 2 Tightening Tightening Torque Specification W1 2 1 Torque Chart W1 2 3 Piping Joint W1 2 6 ...

Page 3: ...167W 1 2 Blank ...

Page 4: ...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 at tempt to remove it forcibly Find the cause s then take the appropriate measures to remove it Orderly arrange disassembled parts Mark and tag them...

Page 5: ...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 upper side hose on travel motor swing motor removed fill the motor case with hydraulic oil Bleeding Air from Hydraulic Circuit After refilling hydraulic oil st...

Page 6: ...age will occur Be sure to do the following to prevent trou ble 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 com pressed air 2 Clean the floating seal and seal mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger 3 Check that the O ring is not ...

Page 7: ... dimensions are shown with tolerances as neces sary Allowable Limit 1 Normal machine performance cannot be accom plished after exceeding this limit 2 Repair or replacement is required before reaching this limit Machine performance will decrease and maintenance and down time expense will increase as machine op erating hours accumulate It is recommended that parts are repaired or replaced before rea...

Page 8: ...ing bolt 16 8 24 205 21 152 5 ORS fittings for hydraulic hoses and piping 1 3 16 12UNF 1 7 16 12UNF 36 41 175 205 18 21 130 152 6 Pump transmission mounting bolt 7 16 14UNF 14 16 69 7 51 7 Pump device mounting bolt 20 8 30 390 40 290 8 Control valve mounting bolt 20 4 30 390 40 290 9 Swing device mounting bolt Ring gear housing mounting bolt hexagonal wrench 22 18 26 24 32 14 740 295 75 30 540 215...

Page 9: ...6 930 95 690 18 Track guard mounting bolt LC LCH 24 24 36 930 95 690 19 Track frame mounting bolt 33 36 50 2160 225 1590 Coupling 8 13 10 5 to 12 5 10 5 to 1 26 7 6 to 9 1 20 Coupling and clamp of low pres sure piping Clamp 1 4 28UNF 11 5 9 0 6 4 3 21 Counterweight mounting bolt Counterweight retaining bolt 45 24 2 4 65 36 2750 440 280 45 2030 330 22 Front pin retaining bolt Front pin retaining nu...

Page 10: ... M Bolt Bolt Dia Wrench Size Hexagon Wrench Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M 8 13 6 29 5 3 22 19 5 2 14 5 9 8 1 7 2 M 10 17 8 64 6 5 47 49 5 36 19 5 2 14 5 M 12 19 10 108 11 80 88 9 65 34 3 5 25 5 M 14 22 12 175 18 130 137 14 101 54 5 5 40 M 16 24 14 265 27 195 205 21 152 78 8 58 M 18 27 14 390 40 290 295 30 220 118 12 87 M 20 30 17 540 55 400 390 40 290 167 17 123 M 22 32...

Page 11: ...e Bolts that are too short cannot develop sufficient tightening force 4 The torques given in the chart are for general use only Torque as specified 5 Make sure that the nut and bolt threads are clean before installing Remove dirt or corrosion if any Bolt Tightening Order When tightening two or more bolts tighten them al ternately as shown to ensure even tightening W105 01 01 003 Tighten diagonally...

Page 12: ...ot to pinch the O ring 4 Tighten bolts alternately and diagonally as shown to ensure even tightening 5 Do not use air wrenches Using an air wrench often causes tightening of one bolt fully before tighten the others resulting in damage to O rings or uneven tightening of bolts Nut and Bolt Lockings Lock Plate IMPORTANT Do not reuse lock plates Do not try to bend the same point twice Cotter Pin IMPOR...

Page 13: ...ealing faces 4 or 5 will cause oil to leak at the joint Take care not to damage the sealing faces when connecting or disconnecting the union joint M202 07 051 W105 01 01 017 Wrench Size mm Tightening Torque Union Joint Union Nut Joint Body N m kgf m lbf ft 30 Male 19 22 27 36 41 50 60 70 19 22 27 36 41 50 60 70 59 6 98 10 118 12 235 24 295 30 490 50 670 68 980 100 43 72 87 134 215 360 490 720 37 F...

Page 14: ... groove O ring 6 will be damaged causing oil leaks 3 Take care not to damage O ring groove 8 on adapter 7 and sealing face 10 of the hose end Damaged O ring 6 will cause oil leaks 4 If oil leaks due to looseness of union nut 9 always replace O ring 6 with new one and check that the O ring is correctly seated in O ring groove 8 before re tightening union nut 9 M104 07 033 Wrench Size Tightening Tor...

Page 15: ...hreads as shown Wrap seal tape in the same direction as the threads Low Pressure Hose Clamp Tightening Torque Low pressure hose clamp tightening torque differs depending on the type of clamp See below for correct tightening torque of each type of low pressure hose clamp T Bolt Type Band Clamp 4 4 N m 0 45 kgf m 3 25 lbf ft Worm Gear Type Band Clamp 5 9 to 6 9 N m 0 6 to 0 7 kgf m 4 3 to 5 1 lbf ft...

Page 16: ...t to a kinked hose may result in oil leakage hose rupture or separation of fitting Utilize print marks on hoses when installing hoses to check if hoses are installed properly 3 If hoses contact each other wear on the hoses will result leading to hose rupture Take necessary measures to protect hoses from contacting each other Take care that hoses do not come into contact with moving parts or sharp ...

Page 17: ...GENERAL INFORMATION Tightening W1 2 10 Blank ...

Page 18: ...lot Pump W2 3 24 Group 4 Control Valve Remove and Install Control Valve W2 4 1 Disassemble Control Valve 1 W2 4 4 Assemble Control Valve 1 W2 4 8 Disassemble Control Valve 2 W2 4 14 Assemble Control Valve 2 W2 4 16 Disassemble Control Valve 3 W2 4 18 Assemble Control Valve 3 W2 4 24 Disassemble Control Valve 4 W2 4 30 Assemble Control Valve 4 W2 4 32 Disassemble Control Valve 5 W2 4 34 Assemble Co...

Page 19: ...p 7 Pilot Shut Off Valve Remove and Install Pilot Shut off Valve W2 7 1 Disassemble Pilot Shut off Valve W2 7 4 Assemble Pilot Shut off Valve W2 7 6 Group 8 Shockless Valve Remove and Install Front Attachment Shockless Valve W2 8 1 Disassemble and Assemble Front Attachment Shockless Valve W2 8 4 Remove and Install Travel Shockless Valve W2 8 7 Disassemble and Assemble Travel Shockless Valve W2 8 8...

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