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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2013, 12
PART NO.
WAFAJ0-EN-00
Workshop Manual
ZX68USR
Hydraulic Excavator
Service Manual consists of the following separate Part No.
Technical Manual
Workshop Manual
Engine Manual
-5A
: Vol. No.TAFAJ0-EN
: Vol. No.WAFAJ0-EN
: Vol. No.ETADB-EN, EWADB-EN
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Table of Contents
Related Manuals for Hitachi ZX68USR-5A
Summary of Contents for Hitachi ZX68USR-5A
- Page 1 PART NO. WAFAJ0-EN-00 Workshop Manual ZX68USR Hydraulic Excavator URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual : Vol. No.TAFAJ0-EN Workshop Manual : Vol. No.WAFAJ0-EN PRINTED IN JAPAN (K) 2013, 12 Engine Manual : Vol. No.ETADB-EN, EWADB-EN...
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Page 3: Additional References
FAX: 81-29-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com 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, the Workshop ... -
Page 4: Units Used
INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicates potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death. - Page 5 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation Technical manual (Operational principle) Technical manual (Operational Principle). Technical manual (Troubleshooting) Technical manual (Troubleshooting). Technical manual Technical manual. W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). E-ECU Engine Controller Engine controller.
- Page 6 SYMBOL AND ABBREVIATION (Blank) SY-2...
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Page 7: Recognize Safety Information
SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ... -
Page 8: Follow Safety Instructions
Hitachi Warranty Policy. Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine... -
Page 9: Prepare For Emergencies
SAFETY 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 to use it properly. ... -
Page 10: Protect Against Noise
SAFETY 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 ... -
Page 11: General Precautions For Cab
SAFETY General Precautions for Cab Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident. -
Page 12: Use Handrails And Steps
SAFETY Use Handrails 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. Be sure you have adequate footing on the crawler when getting on or off the machine. -
Page 13: Ensure Safety Before Rising From Or Leaving Operator's Seat
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat Before rising from the operator’s seat to open/close either 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. -
Page 14: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely Bystanders can be run over. 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). -
Page 15: Jump Starting
SAFETY Jump Starting Battery gas can explode, resulting in serious injury. If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. The operator must be in the operator’s seat so that the machine will be under control when the engine starts. -
Page 16: Precautions For Operations
SAFETY Precautions for Operations Investigate the work site before starting operations. 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. -
Page 17: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing. -
Page 18: Install Opg Guard
Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, equip Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. The guard can be compliant with ROPS standards depending on the machine specifications. -
Page 19: Provide Signals For Jobs Involving Multiple Machines
SAFETY Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple 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 directions. SA-481 Confirm Direction of Machine to Be Driven ... -
Page 20: Drive Machine Safely
SAFETY Drive Machine Safely 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. - Page 21 SAFETY When the machine descends a slope at high speed, machine weight accelerates descending speed. It may cause collision accident due to misjudging of braking distance or machine turnover due to running on an unexpected obstacle. Always ensure that travel mode display (1) on the monitor , and then reduce the engine speed before descending a slope.
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Page 22: Avoid Injury From Rollaway Accidents
SAFETY Avoid Injury from Rollaway Accidents Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: Select level ground when possible to park the machine. Do not park the machine on a grade. ... -
Page 23: Avoid Injury From Back-Over And Swing Accidents
SAFETY Avoid Injury from Back-Over and Swing Accidents If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: ... -
Page 24: Keep Person Clear From Working Area
SAFETY Keep Person Clear from Working Area A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. Keep all persons clear from the area of operation and machine movement. -
Page 25: Avoid Undercutting
SAFETY 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. -
Page 26: Never Undercut A High Bank
SAFETY Never Undercut a High Bank The edges could collapse or a land slide could occur causing serious injury or death. SA-1302 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. -
Page 27: Avoid Power Lines
SAFETY 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 plus twice the line insulator length. -
Page 28: Object Handling
SAFETY Object Handling If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. When using the machine for craning operations, be sure to comply with all local regulations. -
Page 29: Park Machine Safely
SAFETY Park Machine Safely To avoid accidents: Park machine on a firm, level surface. Lower bucket to the ground. Turn auto-idle switch OFF. Run engine at slow idle speed without load for 5 minutes. Turn key switch to OFF to stop engine. ... -
Page 30: Transport Safely
2. Always use a ramp or deck strong enough to support the machine weight. 3. Push auto-idle switch (1) to turn A/I display (2) OFF. (ZX68USR-5A) 4. Select the slow travel mode for loading or unloading the machine. Always ensure that travel mode display (3) on the monitor is , before traveling the machine. -
Page 31: Practice Safe Maintenance
SAFETY Practice Safe Maintenance To avoid accidents: Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab. Never lubricate or service the machine while it is moving. ... -
Page 32: Warn Others Of Service Work
SAFETY 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. -
Page 33: Support Machine Properly
SAFETY 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. -
Page 34: Prevent Parts From Flying
SAFETY Prevent Parts from Flying Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. ... -
Page 35: Prevent Burns
SAFETY Prevent Burns Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. ... -
Page 36: Replace Rubber Hoses Periodically
SAFETY Replace Rubber Hoses Periodically Rubber hoses that contain flammable fluids 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 inspection alone. ... -
Page 37: Prevent Fires
SAFETY Prevent Fires Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires. Check for oil leaks due to 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. - Page 38 SAFETY Clean up 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 adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.
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Page 39: Evacuating In Case Of Fire
SAFETY Evacuating in Case of Fire If a fire breaks out, evacuate the machine in the following way: Stop the engine by turning the key switch to the OFF position if there is time. Use a fire extinguisher if there is time. ... -
Page 40: Precautions For Welding And Grinding
SAFETY 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. -
Page 41: Avoid Applying Heat To Lines Containing Flammable Fluids
Keep the units away from open flames and fire. Do not attempt to bore a hole or cut by torch. Avoid giving shocks by hitting or rolling the unit. Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. SA-35... -
Page 42: Remove Paint Before Welding Or Heating
Keep bystanders out of the work site during operation. Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts. SA-36... -
Page 43: Prevent Battery Explosions
SAFETY 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. ... -
Page 44: Handle Chemical Products Safely
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. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. -
Page 45: Never Ride Attachment
SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice. Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal. - Page 46 SAFETY (Blank) SA-40...
- Page 47 Group 6 Upper and Lower Roller reserved to make changes at any time Group 7 Track without notice. Group 8 Blade Cylinder SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder COPYRIGHT(C)2013 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
- Page 48 TECHNICAL MANUAL SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Revolution Sensing Valve Group 3 Swing Device Group 4 Control Valve Group 5 Pilot Valve...
- Page 49 SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ..............W1-1-1-1 Group 2 Tightening Tightening Bolts and Nuts ..........W1-2-1-1 Piping Joint ..............W1-2-1-4 Group 3 Painting Painting ................W1-3-1-1 Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank ......W1-4-1-1 Bleeding Air from Hydraulic System .......W1-4-1-2 Bleeding Air from Fuel System ........W1-4-1-3 Bleeding Air from Radiator .........W1-4-1-4...
- Page 50 (Blank) AFAJ0W-1-2...
- Page 51 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and If a part or component cannot be removed after Assembling 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.
- Page 52 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures: ...
- Page 53 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners.
- Page 54 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right.
- Page 55 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. “Allowable Limit” 1.
- Page 56 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank) W1-1-1-6...
- Page 57 SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts 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 injure.
- Page 58 SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it) Torque tolerance is ±10 %.
- Page 59 SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt Flange IMPORTANT: Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the WDAA-01-02-005 O-ring. Use only specified O-rings.
- Page 60 SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT: The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque. Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.