Hitachi zaxis zx 60 usb 3f excavator service repair manual

INTRODUCTION
IN-01
ADDITIONAL REFERENCES
Please refer to the other materials (operator’s
manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.
MANUAL COMPOSITION
This manual consists the Technical Manual and the
Workshop Manual.
• 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

INTRODUCTION
IN-02
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
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.
CAUTION:
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.
Example : 24.5 MPa (250 kgf/cm2
, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity
To Convert
From
Into Multiply By
MPa kgf/cm
2
10.197Pressure
MPa psi 145.0
kW PS 1.360Power
kW HP 1.341
Temperature C F C 1.8+32
km/h mph 0.6214Velocity
min
-1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
Quantity
To Convert
From
Into Multiply By
mm in 0.03937Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m
3
yd
3
1.308
Weight kg lb 2.205
N kgf 0.10197Force
N lbf 0.2248
N m kgf m 1.0197Torque
N m lbf ft 0.7375

SAFETY
SA-1
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 do not use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
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-1223

SAFETY
SA-2
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, or-
der a replacement from your authorized 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 personnel
to operate the machine.
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.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident, machine
trouble, and/or damage to material caused by unauthor-
ized modifications will void Hitachi Warranty Policy.
 Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may dete-
riorate the safety, function, and/or service life of the ma-
chine. In addition, personal accident, machine 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 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 au-
thorized dealer before operating or performing mainte-
nance work on the machine.
SA-003
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.
 Keep emergency numbers for doctors, ambulance service,
hospitals, and fire department posted near your tele-
phone.
SA-437

SAFETY
SA-3
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
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.
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.
SA-434
INSPECT MACHINE
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

SAFETY
SA-4
TIDY UP INSIDE OPERATOR’S SPACE
Always keep inside the operator’s space clean by ob-
serving instructions below, to prevent any personal ac-
cidents from occurring.
Remove mud and/or oily material from the shoe soles
before entering the operator’s space. If pedals are oper-
ated without removing mud or oily matter, the foot may
slip off the pedal, possibly creating a hazardous situa-
tion.
Do not leave parts and/or tools around the operator’s
seat.
Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly
starting a fire.
Do not wear radio or music headphones and do not use
a cell phone while traveling or operating the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Never allow hazardous materials such as combustible
and/or explosive material in the operator’s space.
Do not leave cigarette lighters in the cab. If the tem-
perature 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 use the
crawler instead of the step for safety. Also get on and
off from the position of the crawler that can secure
your feet space enough.
• 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,
thoroughly remove such material.
SA-439

SAFETY
SA-5
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.
 Adjust the rear view mirror position so that the best
rear visibility is obtained from the operator’s seat. If the
mirror is broken, immediately replace it with a new
one.
SA-378
ENSURE SAFETY BEFORE RISING FROM OR
LEAVING OPERATOR’S SEAT
Before rising from the operator’s seat to open/close ei-
ther side window or to adjust the seat position, be sure to
first lower the front attachment to the ground and then
move the pilot control shut-off lever to the LOCK position.
Failure to do so may allow the machine to unexpectedly
move when a body part unintentionally comes in contact
with a control lever, possibly resulting in serious personal
injury or death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the
key switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors,
and access covers and lock them up.
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

SAFETY
SA-6
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-
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. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
SA-1291

SAFETY
SA-7
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.
 Before starting the engine, confirm that all control lev-
ers are in neutral.
 Before starting the engine, confirm the safety around
the machine and sound the horn to alert bystanders.
SA-444
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
could result in a battery explosion or a runaway ma-
chine.
SA-032
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

SAFETY
SA-8
PRECAUTIONS FOR OPERATIONS
Thoroughly make certain safety at the work site before
starting operations. Especially always observe the fol-
lowing points.
• Be sure to install the overhead cab guard before op-
erating the machine in areas where the possibility of
falling stones or debris exists.
• If operation on soft ground is required, sufficiently re-
inforce the ground beforehand.
• Be sure to wear close fitting clothing and required
safety items, such as a hard hat, when operating the
machine.
• Keep all bystanders and unnecessary objects out of
and away from the machine working areas. Always
beware of the surroundings while operating the ma-
chine. Take care not to allow the rear part of the up-
perstructure to come in contact with objects when
swinging the machine in a small area.
• When loading a dump truck, bring the bucket from the
rear side of the dump truck to avoid moving the bucket
over the dump truck cab or over any co-workers.
M586-12-012

SAFETY
SA-9
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 col-
lapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges, and road shoulders as neces-
sary. Keep the machine well back from the edges of ex-
cavations and road shoulders.
 When working on an incline or on a road shoulder, employ
a signal person as required.
 Never allow bystanders to enter the working area such as
swing radius or traveling range.
 When the footing is weak, reinforce the ground before
starting work.
 Confirm that your machine is equipped a FOPS cab be-
fore working in areas where the possibility of falling stones
or debris exist.
 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 spe-
cial care not to cause a fire.
 Make sure the work site ground has sufficient strength to
firmly support the machine. When working close to an
excavation or on road shoulders, operate the machine
with the tracks positioned perpendicular to the cliff face
with travel motors at the rear and with the blade at the
front, so that the machine can more easily evacuate if the
cliff face collapses.
 If working at the bottom of a cliff or on a high bank is re-
quired, be sure to investigate the area first and confirm
that no danger of the cliff or bank collapsing exists. If any
possibility of cliff or bank collapsing exists, do not work in
that area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on a soft ground is required, be sure to reinforce the
ground first using large pieces of steel plates strong
enough and firm to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with ma-
chine movements.
SA-1293
M586-05-021

SAFETY
SA-10
PROTECT AGAINST FALLING STONES AND
DEBRIS
Confirm that your machine is FOPS cab equipped before
working in areas where the possibility of falling stones or
debris exist.
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 levers are operated to the front
.
SA-1294

SAFETY
SA-11
DRIVE MACHINE SAFELY
Driving the machine in the incorrect direction may result
in serious injury or death and/or severe damage to
property.
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the
direction you wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Do not allow personnel to stay around the
machine while traveling.
Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 30 degrees or
steeper slopes.
• Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 200 to 300
mm (8 to 12 in) (A) above the ground.
 If machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If the
direction must be changed, move the machine to level
ground, then, change the direction to ensure sage
operation.
 Avoid swinging the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, return the control levers
to neutral. Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not
warmed up sufficiently, sufficient driving power to
ascend may not be obtained.
SA-1295
SA-1296
SA-441
SA-442
A
A

SAFETY
SA-12
• Traveling down a slope in the fast mode requires a
longer time to stop the machine. When traveling down
a slope, placing travel mode switch (1) in the TURTLE
position is recommended.
• Select a travel route that is as flat as possible. Steer
the machine as straight as possible, making small
gradual changes repeatedly in direction.
• Check the strengths of bridges and road shoulders
before traveling on them, and reinforce if necessary.
• When the machine is equipped with steel shoes, cover
the road surface with wood plates in order not to
damage the road surface. Be careful of steering when
operating on asphalt roads in summer.
• When crossing train tracks, lay wood plates over the
tracks not to allow the machine to ride on only the
rails.
• Check that the machine can pass under a bridge and
electric lines before driving the machine.
• When crossing a river, drive the machine slowly while
measuring the depth of the river using the bucket. Do
not cross the river when the depth of the river is
deeper than the upper track shoe surface.
• Reduce the engine speed when traveling on rough
terrains. Select slow a travel speed. Slower speed will
reduce possible damage to the machine.
• Drive the machine so that the travel motors do not
come in contact with loose rocks. If the machine
crosses over an obstruction, abnormally large loads
may be loaded on the machine. Avoid contact with an
obstruction while traveling the machine.
• During freezing weather, always clean snow and ice
from track shoes before driving the machine on snowy
and/or frozen roads, or loading and unloading the
machine for transportation, to prevent the machine
from slipping.
M1M0-06-001
M104-05-008
SA-673
M586-05-002
1
Travel Motor

SAFETY
SA-13
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 SA-19 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

SAFETY
SA-14
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).
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.
• 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-383
SA-384

SAFETY
SA-15
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

SAFETY
SA-16
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
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.
• 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
SA-1301
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could occur
causing serious injury or death.
SA-1302

SAFETY
SA-17
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
area, and/or the utility companies directly.
Have them mark all underground utilities.
SA-672
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
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-1305

SAFETY
SA-18
PRECAUTIONS FOR LIGHTNING
The machine is vulnerable to lightning strikes.
• In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground.
Evacuate to a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only
after repairing them.
SA-1805
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

SAFETY
SA-19
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.
• Pull the lock lever to the LOCK position.
• Turn the auto-idle switch 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
SA-1306
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.
• 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.
• Securely tighten the fuel and oil filler cap.
SA-018
SA-019

SAFETY
SA-20
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.
• 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. Be sure to turn the auto-idle switch (1) OFF.
5. Slowly drive the machine.
6. 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.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
9. Do not operate any levers besides the travel levers
when driving up or down the ramp.
10. Prevent possible injury from machine tipping while the
upperstructure is rotating.
11. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
Refer to "transporting" chapter in operator’s manual for
details.
SA-1307
M1M7-01-028
M1M0-06-001
less than 15 degrees
1

SAFETY
SA-21
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
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
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
machine. Failure to do so may cause personal injury.
• When 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.
• 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-028
M1M7-04-006
SA-527
90 to 110

SAFETY
SA-22
• 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.
• When the floor tilt mechanism check and/or
maintenance is conducted, the operator’s station is
tilted upward. Before conducting maintenance work,
refer to page 7-75 on operator’s manual for the
detailed operation procedures and correctly operate
the machine.
• When required to work under the floor, support the
raised operator’s station with the fall prevention bars
(red color) to ensure safety.
• When the inspection/maintenance work is complete,
tilt the operator’s station downward after housing the
fall prevention bars. Be sure to slowly lower the
operator’s station at the time.
Failure to remove the supporters such as safety lock bar
may damage the tilt mechanism.
SA-037
M1M0-07-032
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

SAFETY
SA-23
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
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.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly
resulting in severe personal injury or death.
Travel reduction gears are under pressure.
• 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 just after operation. Wait for gear oil
to cool, then gradually loosen the air release plug to
release pressure.
SA-344

SAFETY
SA-24
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
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.
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-039
SA-225

SAFETY
SA-25
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
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.
SA-019
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.
• 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-031
SA-292
SA-044

SAFETY
SA-26
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.
• 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-019

SAFETY
SA-27
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.
• Do not store flammable fluid near open flames.
• Do not burn or crush a pressurerized container.
• Do not store oily cloths. They are liable to catch fire.
• Do not 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.

SAFETY
SA-28
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.
Refer to the explanation pages on the Emergency
Evacuation Method in the operator’s manual.
SA-393
SS4642980
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
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer.
• Depending on the wok site conditions, the risk of
inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Do not use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.
SA-029

SAFETY
SA-29
PRECAUTIONS FOR WELDING AND
GRINDING
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
grinding.
After finishing welding and grinding, recheck that there
are no abnormalities such as the area surrounding the
welded area still smoldering.
SA-818
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,
etc.
SA-030
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.

SAFETY
SA-30
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.
• 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.
SA-029
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.
• When a terminal becomes 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-032

SAFETY
SA-31
PRECAUTIONS FOR HANDLING
REFRIGERANT
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.
• See your authorized dealer for MSDS. SA-309
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
such as oil, fuel, coolant, brake fluid, filters, and
batteries from your local environmental or recycling
center.
SA-226

SAFETY
SA-32
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
S517-E01A-0435 SA-435

SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
SECTION 1 GENERAL
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
Group 5 Floor-Tilting Device
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 2-Spool Solenoid Valve
Group 8 Revolution Sensing Valve
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

TECHNICAL MANUAL
SECTION 1 GENERAL
Group 1 Specifications
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 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

1N0W-1-1
SECTION 1
GENERAL
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............................................ W1-2-3
Piping Joint.............................................. W1-2-6
Periodic Replacement of Parts ...............W1-2-11
Group 3 Painting
Painting ................................................... W1-3-1
Group 4 Bleeding Air from Hydraulic Oil
Tank
Bleed Air from Hydraulic Oil Tank ............ W1-4-1
Group 5 Floor-Tilt Mechanism
Procedure for Floor Tilt Mechanism......... W1-5-1
Floor Tilt Up............................................. W1-5-2
Floor Tilt Down ........................................ W1-5-5

GENERAL / Precautions for Disassembling and Assembling
W1-1-1
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.

W1-1-2
Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and 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 operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age 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.

W1-1-3
Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1N0-01-04-001

W1-1-4
Floating Seal Precautions
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set
with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(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
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 installed correctly on the seal ring.
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal
mating 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.
W105-03-05-019
W105-03-05-020
W110-03-05-004
A
B
Correct
Incorrect
Incorrect
a=b a b
Correct
aa
bb
D
C

W1-1-5
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings
safely.
• Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the
lifted load balanced.
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
W102-04-02-016
W105-04-01-008
W162-01-01-009
Correct Eyehole
Lifting Method
Incorrect Eyehole
Lifting Method
Bent Sling

W1-1-6
CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
Damaged Appearance
W162-01-01-002
W162-01-01-003
W162-01-01-004
W162-01-01-005
W162-01-01-006
W162-01-01-007
W162-01-01-008
Broken Sewing Thread
Scuffing
Broken Sewing
Thread
Fuzz
Broken Sewing
Thread
Separation of
Belt
Broken Sewing
Thread
Scuffing
Scoring
Broken Warp
Fuzz

W1-1-7
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-
ing this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

GENERAL / Tightening
W1-2-1
TIGHTENING TORQUE SPECIFICATIONS
Torque
No. Descriptions
Bolt Dia.
mm
Q’ty
Wrench
Size
mm N m (kgf m) (lbf ft)
Screw
Thread
1. Engine cushion rubber mounting bolt 14 4 22 140 (14) (100)
2. Engine bracket mounting bolt (Front) 10 8 17 65 (6.5) (48)
3. Muffler mounting nut (with single nut) 10 4 17 10 (1) (7) -
4. Muffler mounting nut (with double nuts) 10 4 17 35 (3.5) (26) -
5. Hydraulic oil tank mounting bolt 12 4 19 90 (9) (65) -
6. Fuel tank mounting nut 10 4 17 50 (5) (37) -
PF1/8 - 19 30 (3) (22)
PF3/8 - 22 40 (4) (30)
PF1/2 - 27 65 (6.5) (48)
PF3/4 - 36 180 (18) (130)
PF1 2 41 210 (21) (160)
Straight thread
PF1-1/4 1 50 250 (25) (180)
7/16-20
UNF
- 17 25 (2.5) (18)
- 19 30 (3) (22)9/16-18
UNF - 22 40 (4) (30)
3/4-16
UNF
- 27 65 (6.5) (48)
1-1/16-1
2UNF
- 36 180 (18) (130)
1-5/16-1
2UNF
- 41 210 (21) (160)
Metal face seal fitting
(37°)
1-5/8-12
UNF
2 50 250 (25) (180)
9/16 -18
UNF
- 19 30 (3) (22)
11/16-16
UNF
- 22 70 (7) (50)
13/16-16
UNF
- 27 95 (9.5) (70)
1-3/16-12
UNF
- 36 180 (18) (130)
7.
Union joints for
hydraulic
hoses and
pipes
ORS
1-7/16-12
UNF
2 41 210 (21) (160)
-
8. T-bolt clamp
1/4-28UN
F
4 11 10 (1) (7) -
9. Pump mounting bolt 12 4 19 90 (9) (65)
10. Pump cover mounting bolt 10 12 17 50 (5) (37) -

W1-2-2
Torque
No. Descriptions
Bolt Dia.
mm
Q’ty
Wrench
Size
mm N m (kgf m) (lbf ft)
Screw
Thread
11. Control valve mounting bolt 10 4 17 50 (5) (37)
12. Control valve base mounting bolt 10 4 17 50 (5) (37) -
13. Swing device mounting bolt 16 8 24 270 (27) (200)
14. Battery mounting nut 6 3 10 5 (0.5) (4) -
10 7 17 50 (5) (37) -
15. Cab mounting bolt
12 6 19 90 (9) (66) -
16. Cab cushion rubber (rear) mounting bolt 16 2 24 210 (21) (160)
Upperstructure 14 33 22 180 (18) (130) -
17.
Swing bearing
mounting bolt Undercarriage 14 24 22 180 (18) (130) -
18. Travel device mounting bolt 14 24 22 220 (22) (160)
19. Sprocket mounting bolt 14 24 22 220 (22) (160)
20. Upper roller mounting bolt 16 2 24 210 (21) (160)
21. Lower roller mounting bolt 20 18 30 620 (62) (460)
22. Track shoe bolt (Optional) 12 312 19 165 (16.5) (120) -
6 - 10 5 (0.5) (4) -
8 - 13 10 (1) (7) -23. Cover mounting bolt
10 - 17 50 (5) (37) -
24. Counterweight mounting bolt 24 3 36 930 (93) (690) -
25.
Additional Counterweight mounting bolt
(Optional)
20 2 30 540 (54) (400) -
10 - 17 50 (5) (37)
12 - 19 90 (9) (66)
14 - 22 140 (14) (100)
16 - 24 210 (21) (160)
26. Front pin lock plate bolts
18 - 27 400 (40) (300)
27.
Track roller guard mounting bolt
(Optional)
14 12 22 140 (14) (100)
28. Tilt mechanism floor connection pins 10 1 17 50 (5) (37)
29. Tilt mechanism support-holding bolts 10 2 17 50 (5) (37)
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.
(3) When installing new bolts and/or
nuts and retightening them, apply
LOCKTITE to the screw threads.

W1-2-3
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.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or
components.
SA-040
Specified Tightening Torque Chart
M552-07-091
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) (22.5) 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 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)

W1-2-4
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no
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.
W105-01-01-003
1
6
4
2
3
Equally tighten upper and lower Tighten diagonally
Tighten from center and diagonally
1st to 4th
2nd to 3rd
13 1110
1412 7614
3258
9
5

W1-2-5
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.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and
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
tightening of the others,
resulting in damage to O-rings or
uneven tightening of bolts.
Nut and Bolt Locking
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while
tightening, not while loosening.
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
Bend along edge sharply Do not bend it round
Bend along edge sharply
Loosen
Tighten
WRONG
RIGHTRIGHT
RIGHT
WRONG
WRONG
RIGHT WRONG
WRONGRIGHTRIGHT

W1-2-6
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
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).
Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten nut (3) to
specifications.
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, 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.
37°
30°
Female Union JointMale Union Joint
1 3 5 2
Joint Body
4

W1-2-7
Piping Joint
Pipe Joint (Metal Joint)
(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.
Tightening Torque Chart
Wrench Size (mm) 17
N m 39
(kgf m) (4.0)
Tightening
Torque
(lbf ft) (29)
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.
2. Before tightening nut (9), confirm
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
in oil leakage.
3. Take care not to damage O-ring
groove (8) or sealing surface
(10).
Damage to O-ring (6) will cause
oil leakage.
4. If nut (9) is loose and oil is
leaking, do not re-tighten nut (9).
Replace O-ring (6) with a new
one and check that O-ring (6) is
correctly seated in place, tighten
nut (9).
M1M7-07-005
M104-07-033
Wrench Size
mm
Wrench Size
mm
Tightening Torque
Union Nut Hose Fittings N m (kgf m, lbf ft)
19 17 29.5 (3.0, 22)
22 19 69 (7.0, 51)
27 22 93 (9.5, 69)
36 30, 32 175 (18, 129)
41 36 205 (21, 151)
7 6 9
8 10
Hose Fittings
1 4 5 3 2

W1-2-8
Quick Coupler
1. Connection Procedure
• 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).
Be sure to check that socket ring (1) has been
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.
M1M7-07-006
3 1
2

W1-2-9
Screw-In Connection
Depending on types of screw and sealing, different
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Seal Tape Application
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks
between threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
Application Procedure
Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs
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 kgf m, 4.3 to 5.1 lbf ft)
W105-01-01-018
Male Tapered Thread
Wrench Size
mm
Tightening Torque
N m (kgf m, lbf ft)
Hose Fittings FC material SS material
19 14.5 (1.5, 10.5) 34 (3.5, 25)
22 29.5 (3.0, 21.5) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16, 116)
41 108 (11, 80) 205 (21, 151)
50 157 (16, 116) 320 (33, 235)
60 195 (20, 144)
W105-01-01-019
M114-07-041
M114-07-043 M114-07-042
PF
30°
PT
Male Straight ThreadMale Tapered Thread
Clearance
External Thread
Internal Thread
Leave one to two pitch threads uncovered
T-Bolt Type Worm Gear Type

W1-2-10
Connecting Hose
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.
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, 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
W105-01-01-013
W105-01-01-014
Rubbing Against
Each Other
RIGHT
RIGHT
RIGHT
RIGHT
WRONG
WRONG
WRONG
WRONG
Rubbing Against
Each Other
Rubbing Against
Each Other
Clamp
ClampClamp

W1-2-11
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
Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Engine rubber vibration insulator
Every 5 years or 4000 hours
whichever comes first
Floor mount rubber
Engine
Pump coupling
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Swing hose Every 2 years
Auxiliary hose Every 2 years
Base Machine
Oil cooler hose (C/V to oil cooler) Every 2 years
Boom cylinder line hose Every 2 years
Arm cylinder line hose Every 2 years
Bucket cylinder line hose Every 2 years
Hydraulic
System
Front
Attachment
Pilot hose Every 2 years
Seat Belt Every 3 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.

GENERAL / Painting
W1-3-1
PAINTING
Surfaces to Be Painted Painting Color
Main surface of upperstructure [Resin covers are excluded]
Swing post, Swing Cylinder
Cab
Seat base, Floor plate [Resin covers are excluded]
Track, Blade
SP-424 [Dark gray]
Front, Upperstructure cover part YR1-01 [TAXI yellow]
Counterweight
Outer cover [rear left, rear right]
SP-424 [Dark gray],
YR1-01 [TAXI yellow]
Control Lever [travel, blade] N1.0 [Black]
W1N0-01-03-001
TAXI Yellow
Black
Dark Gray
TAXI Yellow
Dark Gray
TAXI Yellow
Dark Gray
TAXI Yellow
TAXI Yellow
TAXI Yellow
TAXI Yellow
Dark Gray
[Including boom
swing cylinder]
Dark Gray
Dark
Gray
Dark Gray
Dark Gray Dark Gray
Dark Gray
Dark Gray
[Including
blade cylinder]

GENERAL / Bleeding Air from Hydraulic Oil Tank
W1-4-1
BLEEDING AIR FROM HYDRAULIC OIL
TANK
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.
2. Stop the Engine. Loosen cap (1) of hydraulic oil
tank (2). Bleed air from hydraulic oil tank.
3. Remove cap (1) of hydraulic oil tank (2).
4. Connect a vacuum pump with the hole removed
cap (1) to maintain negative pressure in the
hydraulic oil tank (2).
NOTE: Be sure to run the vacuum pump
continuously while working.
W1N0-01-04-001
W1M9-01-04-001
W1M9-01-04-002
Vacuum Pump
Hose
2
1
Adapter

GENERAL / Floor Tilt Mechanism
W1-5-1
PROCEDURE FOR FLOOR TILT
MECHANISM
Preparation:
1. Park the machine on a solid and level ground.
2. Lower the blade.
IMPORTANT: Do not tilt up the floor while raising
the front attachment. Otherwise, the
boom may contact with the cab.
3. Lower the front attachment on a wooden block
with the arm and the bucket rolled in.
IMPORTANT: Do not tilt up the floor while opening
the door. Otherwise, the door may
contact with the exterior cover.
4. Shut the cab door.
W1N0-01-05-001
Wooden Block

W1-5-2
FLOOR TILT UP
IMPORTANT: If the floor is tilted up by hoisting,
the floor tilt mechanism may be
damaged. Tilt up the floor as the
procedure shown below.
1. Loosen bolts (3) (2 used). Move cover (2) to the
upper end.
Temporarily install cover (2) to cab (1) with bolts
(3) (2 used).
: 12 mm
IMPORTANT: Do not remove bolts (18) (2 used) as
bolts (18) are used for installing the
cab bracket (2).
The bolts which should not be
removed are provided with a cap or
colored red in order not to confuse.
2. Remove bolts (4) (4 used) from cab bracket (19).
: 19 mm
3. Remove fall prevention bar (6) from the pocket at
the rear side of seat (5).
M1M0-07-034
M1M0-07-035
M1MF-07-041
5
6
1
2
3
4
1
18 19

W1-5-3
IMPORTANT: Operating torque of adjuster screw
(7) should be 25 N m (2.5 kgf m, 18.5
lbf ft) or lower. If operating torque
requires more than 25 N m (2.5 kgf m,
18.5 lbf ft), bolt (4) may not have
been removed.
4. Turn adjuster screw (7). Tilt the cab (1) assembly
to the front side.
: 17 mm
5. Turn adjuster screw (7) clockwise until disc (8) at
the tilt mechanism side is located at 5 mm before
the end position.
M1M0-07-035
M1M0-07-034
M1M0-07-036
7
8
5 mm
4
1
7

W1-5-4
IMPORTANT: Do not squash the hose and the
harness with fall prevention bar (6).
6. Turn lock stopper (10) to position A.
7. Set fall prevention bar (6) to main frame (9).
8. Turn lock stopper (10) to position B and lock it.
M1MF-07-042
M1M0-07-032
6
9
10
6

W1-5-5
FLOOR TILT DOWN
1. Turn lock stopper (10) to position A.
2. Remove fall prevention bar (6) from main frame
(9).
IMPORTANT: If the floor is tilted down while
setting lock stopper (10) vertically at
position A, lock stopper (10) may
interfere and damage the hose and
the harness.
3. Turn lock stopper (10) to position B.
M1M0-07-032
M1MF-07-042
6
9
10
6

W1-5-6
CAUTION: Do not lower the floor rapidly. If
adjuster screw (7) is turned rapidly while
lowering the floor, the floor shakes greatly.
4. Slowly turn adjuster screw (7) counterclockwise.
: 17 mm
5. Turn adjuster screw (7) counterclockwise until the
end of bracket (11) contacts plate (12).
CAUTION: If continuously turning adjuster
screw (7) after the floor is lowered completely,
washer (15) contacts the pin (16) end when
adjuster screw (7) comes toward the front
attachment 15 mm. so that adjuster screw (7)
cannot be turned. If continuously turning
adjuster screw (7) furthermore, washer (15)
may be deformed and damaged, or bolt (17)
may fall off.
6. When the floor is lowered completely, adjuster
screw (7) comes toward the front attachment.
Adjust the clearance between flange (14) of
adjuster screw (7) and contacting surface (13) to 2
to 5 mm.
M1M7-07-068
W1M9-01-05-002
M1M7-07-075
12
11
7
15 16
17
13
7
14
2 to 5 mm

W1-5-7
7. Install fall prevention bar (6) to the pocket at the
rear side of seat (5).
8. Install cab bracket (19) with bolts (4) (4 used).
: 19 mm
: 90 N m (9 kgf m, 66 lbf ft)
9. Loosen bolts (3) (2 used). Move cover (2) to the
lower end.
Secure cover (2) to cab (1) with bolts (3) (2 used).
M1MF-07-041
M1M0-07-035
M1M0-07-034
5
6
4
1
2
3

ME MO
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1N0W-2-1
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Removal and Installation of Cab.............. W2-1-1
Dimensions of Cab Glass ........................ W2-1-9
Group 2 Counterweight
Removal and Installation of
Counterweight ....................................... W2-2-1
Group 3 Pump Device
Pump Device ......................................... W2-3-1
Disassembly of Pump Device ................ W2-3-6
Assembly of Pump Device..................... W2-3-12
Disassembly of Regulator...................... W2-3-20
Assembly of Regulator .......................... W2-3-22
Maintenance Standard........................... W2-3-26
Control Valve ......................................... W2-4-1
Disassembly and Assembly of
Control Valve ......................................... W2-4-4
Removal and Installation of Relief Valve
and Make-up Valve .............................. W2-4-12
Disassembly and Assembly of Body .... W2-4-14
Disassembly of Unload Section ............. W2-4-16
Assembly of Unload Section.................. W2-4-18
Disassembly and Assembly of Spool ..... W2-4-20
Disassembly and Assembly
Boom Anti-Drift Valve........................... W2-4-22
Disassembly and Assembly of
Shuttle Valve and Pressure
Compensation Valve............................ W2-4-24
Swing Device ......................................... W2-5-1
Disassembly of Swing Device .................. W2-5-4
Assembly of Swing Device....................... W2-5-6
Disassembly of Swing Motor.................. W2-5-12
Assembly of Swing Motor....................... W2-5-14
Maintenance Standard ........................... W2-5-18
Group 6 Pilot Valve
Removal and Installation of Pilot Valve .... W2-6-1
Disassembly of Left and Right
Pilot Valves .......................................... W2-6-16
Assembly of Left and Right
Pilot Valves .......................................... W2-6-20
Disassembly of Travel Pilot Valve .......... W2-6-24
Assembly of Travel Pilot Valve ............... W2-6-28
Disassembly of Pilot Valves for
Boom Swing, Blade and Auxiliary......... W2-6-34
Assembly of Pilot Valves for
Boom Swing, Blade and Auxiliary......... W2-6-36
Group 7 2-Spool Solenoid Valve
2-Spool Solenoid Valve ..........................W2-7-1
Disassembly of 2-Spool
Solenoid Valve ....................................... W2-7-4
Assembly of 2-Spool Solenoid Valve........W2-7-6
Revolution Sensing Valve ...................... W2-8-1
Disassembly of Revolution
Sensing Valve ........................................W2-8-4
Assembly of Revolution Sensing Valve ....W2-8-6

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