Hitachi EX80-5 Bedienungsanleitung
Manual No. : KM-152E-NA
Vol.No. :TT152E-NA
TechnicalManual
(Troubleshooting)
EXBO-s
Excavator
Service Manual (Manual No. KM-152E-NA} consists of the following three separate volumes;
Technical Manual (Operational Principle} :Vol. No.T0152E-NA
Technical Manual (Troubleshooting)
Workshop Manual
:Vol.No.TT152E-NA
:Vol. No.W152E-NA
HITACHI
INTRODUCTION
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator's Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions:the Technical
Manual (Operational Principle), the Technical Man-
ual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
T 1-3-5
If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using "Service Manual
Revision Request Form" at the end of this man-
ual.
(Note: Donot tear off the form. Copy it for usage.):
Publications Marketing &Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX:81-298-31-1162
Operation Manual of the Engine
Parts Catalog of the Engine
Hitachi Training Material
Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational per-
formance tests, and troubleshooting procedures.
• Information included in the Workshop Manual:
technical information neededfor maintenance and
repair of the machine, tools and devices needed
for maintenance and repair, maintenance stan-
dards, and removal/installation and assem-
ble/disassemble procedures.
Example: 11 : roo,oc••~ oage,,moo, fu, EachGro,p
Group Number
Section Number
'------ T:TechnicalManual W: Workshop Manual
IN-01
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INTRODUCTION
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
potentialfor personal injuryof machine damage.
A This is the safety alert symbol. When you see this
symbol, be alertto the potentialfor 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 componenVpartweights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicatedin parenthhesesjust behind SI units.
Quantity To Convert Into Multiply By
From
Length mm in 0.03937
mm ft 0.003281
Volume L US qal 0.2642
L usqt 1.057
m" yd" 1.308
Weiaht kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N-m kgf-m 1.0197
N-m lbf-ft 0.7375
• AcAUTION:
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.
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 Into Multiply By
From
Pressure MPa kgf/cm' 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature oc OF °Cx1.8+32
Velocity km/h mph 0.6214
min·' rpm 1.0
Flow rate L/min USqpm 0.2642
ml/rev cc/rev 1.0
IN-02
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SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
0
□
1"E'01A-0001
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating
the degreeor level of hazard- DANGER,WARNING,
or CAUTION - are usedwith the safety alert symbol.
DANGER indicates an imminently hazardous
situationwhich, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situationwhich, if not avoided, may result in minor
or moderate injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listedon CAUTION safety signs.
• CAUTION also calls attentionto safety messages in
this manual.
• Toavoid 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.
•tJNOTE indicates an additional explanation for an
elementof information.
□□
2-ED1A-1223
SA-1
SA-001
A DANGER
A WARNING
A CAUTION
IMPORTANT
tJNOTE
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SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
If a safety sign or operator's manual is damaged
or missing, replace itwith new one.
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel to
operate the machine.
• Keep your machine in properworking condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect
machine life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label
attached on the fire extinguisher to use it properly.
Establish emergency procedure guidelines to
copewith fires and accidents.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
posted nearyour telephone.
004-E01A-0437
SA-2
SA-003
SA-437
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SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment
appropriate to thejob.
Youmay need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavygloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for thejob. 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
headphoneswhile operating the machine.
D05--E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause
impairment or loss of hearing.
• Wear a suitable hearing protective devicesuch as
earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
In the walk-around inspection be sure to cover all
points described in the "PRE-START
INSPECTION" chapter in the operator's manual.
SA-3
SA-438
SA-434
SA-435
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SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
When you get on and off the machine, always
face the machine and maintain a three-point
contact withthe stepsand handrails.
Do not useany controls as hand-holds.
Neverjump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrailswhen leavingthe machine.
008-ED1A-0439
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 misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back againstthe seat back.
If not, move the seat forward or backward, and
check again.
SA-4
SA-439
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SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator rnay
become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
Prior to operating the machine, thoroughly
examinewebbing, buckleand attaching hardware.
If any item is damaged or worn, replace the seat
beltor component before operating the machine.
Be sure to remain seated with the seat belt
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanderscan 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). II warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine.
011-E01A-0426
SA-5
SA-237
)
SA-426
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SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possiblyresulting in serious
injury or death.
Start the engine only when seated in the
operator's seal.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
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. Jump starting is a two-person
operation.
Never usea frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
S013-E01A..(]D32
SA-6
SA-444
SA-032
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