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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2013, 10
PART NO.
WAEB-EN-00
Workshop Manual
ZX55U
Hydraulic Excavator
Service Manual consists of the following separate Part No.
Technical Manual
Workshop Manual
Engine Manual
-5A
: Vol. No.TAEB-EN
: Vol. No.WAEB-EN
: Vol. No.ETADB-EN, EWADB-EN
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Summary of Contents for Hitachi ZX55U-5A
- Page 1 PART NO. WAEB-EN-00 Workshop Manual ZX55U Hydraulic Excavator URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual : Vol. No.TAEB-EN Workshop Manual : Vol. No.WAEB-EN PRINTED IN JAPAN (K) 2013, 10 Engine Manual : Vol. No.ETADB-EN, EWADB-EN...
- Page 3 Form” at the end of this manual. (Note: Do not tear off destination may be explained on this manual. the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Be sure to thoroughly read this manual for correct Construction Machinery Co. Ltd.
- Page 4 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...
- Page 7 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 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 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 and use it properly. ...
- Page 10 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 SAFETY General Precautions for Cab Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring. 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.
- Page 12 SAFETY Adjust the Operator’s Seat A poorly adjusted seat for either the operator or 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.
- Page 13 SAFETY Fasten Your Seat Belt If the machine should overturn, the operator may become 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.
- Page 14 SAFETY 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.
- Page 15 SAFETY Precautions for Operations Thoroughly make certain safety at the work site before starting operations. Especially always observe the following points. Be sure to wear close fitting clothing and required safety items, such as a hard hat, when operating the machine. ...
- Page 16 SAFETY 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 collapsing.
- Page 17 In case the machine is operated in areas where the possibility of falling stones or debris exists, equip genuine Hitachi OPG guard. Contact your nearest Hitachi dealer for installation method of the OPG guard. Depending on the specifications applied to your machine, modification of the machine to meet ROPS standards will be possible.
- Page 18 SAFETY Drive Machine Safely Use a signal person when traveling the machine along road shoulders or in congested areas. Driving the machine in the incorrect direction may result in serious injury or death and/or severe damage to property. ...
- Page 19 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.
- Page 20 SAFETY 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 in operator's manual to prevent the machine from running away.
- Page 21 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 22 SAFETY Keep Person 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. ...
- Page 23 SAFETY Avoid Tipping 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. ...
- Page 24 SAFETY 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.
- Page 25 SAFETY 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. ...
- Page 26 SAFETY 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;...
- Page 27 SAFETY 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.
- Page 28 SAFETY Transport Safely 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.
- Page 29 SAFETY 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. ...
- Page 30 SAFETY 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.
- Page 31 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 with stays or blocks strong enough to support the machine and/or attachment weight.
- Page 32 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 FITTINGS or VALVE ASSEMBLIES. ...
- Page 33 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 34 SAFETY 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.
- Page 35 SAFETY 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.
- Page 36 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.
- Page 37 SAFETY 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. ...
- Page 38 Keep the units away from open flames and fire. Do not bore a hole, do not 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-32...
- Page 39 Keep bystanders out of the work site during operation. Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. SA-33...
- Page 40 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 41 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 battery. When draining fluid, use a leakproof container with a capacity larger than the drained fluid volume to receive it.
- Page 42 SAFETY Never Ride Attachment Never allow anyone to ride attachments or the 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 43 SAFETY Precaution for Communication Terminal Equipment A mobile communication terminal which transmits radio wave is located in the monitor cover at front right of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.
- Page 44 (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.) Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broke circuit that may result in damage and/or fire to the base machine or to the communication terminal.
- Page 45 Group 6 Upper and Lower Roller without notice. Group 7 Track 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 46 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 47 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 48 (Blank) AEBW-1-2...
- Page 49 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 50 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 51 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 52 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 53 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 54 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank) W1-1-1-6...
- Page 55 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 56 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 57 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 58 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.
- Page 59 SECTION 1 GENERAL Group 2 Tightening Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter.
- Page 60 SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil. Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.