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

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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.

□

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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