Hitachi ZX 110-3 Workshop Manual Download

Page: 32 / 34

1R7W-2-1

SECTION 2

UPPERSTRUCTURE

CONTENTS

Group 1 Cab

Removal and Installation of Cab

(ZX110-3 class, 120-3 class) ..................... W2-1-1

Removal and Installation of Cab

(ZX135US-3 class) .................................... W2-1-9

Dimensions of Cab Glass

(ZX110-3 class, 120-3 class) ................... W2-1-21

Dimensions of Cab Glass

(ZX135US-3 class) .................................. W2-1-25

Group 2 Counterweight

Removal and Installation of Counterweight

(ZX110-3 Class, 120-3 Class) ................... W2-2-1

Removal and Installation of Counterweight

(ZX135US-3 Class) ................................... W2-2-3

Group 3 Main Frame

Removal and Installation of Main Frame..... W2-3-1

Group 4 Pump Device

Removal and Installation of Pump Device

(ZX110-3 class, 120-3 class) ..................... W2-4-1

Removal and Installation of Pump Device

(ZX135US-3 class) .................................... W2-4-5

Disassembly of Main Pump ....................... W2-4-10

Assembly of Main Pump............................ W2-4-20

Disassembly of Regulator ......................... W2-4-34

Assembly of Regulator .............................. W2-4-36

Disassembly of Solenoid Valve ................. W2-4-38

Assembly of Solenoid Valve ...................... W2-4-40

Disassembly and Assembly of

Gear Pump .............................................. W2-4-42

Disassembly and Assembly of

Gear Pump (Optional) ............................. W2-4-44

Maintenance Standard .............................. W2-4-46

Group 5 Control Valve

Removal and Installation of Control Valve

(ZX110-3 class, 120-3 class) .....................W2-5-1

Removal and Installation of Control Valve

(ZX135US-3 class).....................................W2-5-5

Disassembly of Control Valve

4-Spool Side .............................................W2-5-10

Disassembly of Control Valve

5-Spool Side .............................................W2-5-18

Assembly and Disassembly of

4-Spool Side and 5-Spool Side ................W2-5-24

Assembly of Control Valve 4-Spool Side ...W2-5-26

Assembly of Control Valve 5-Spool Side ...W2-5-32

Disassembly of Blade Control Valve

(Optional)..................................................W2-5-38

Assemble of Blade Control Valve

(Optional)..................................................W2-5-40

Group 6 Swing Device

Removal and Installation of Swing Device

(ZX110-3 class, 120-3 class) .....................W2-6-1

Removal and Installation of Swing Device

(ZX135US-3 class).....................................W2-6-3

Disassembly of Swing Device......................W2-6-6

Assembly of Swing Device.........................W2-6-14

Disassembly of Swing Motor......................W2-6-24

Assembly of Swing Motor ..........................W2-6-28

Disassembly of Valve Unit .........................W2-6-34

Assembly of Valve Unit ..............................W2-6-36

Maintenance Standard ...............................W2-6-38

Summary of Contents for ZX 110-3

Page 1: ......

Page 2: ...RNING 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 don t use any of the desig nated signal...

Page 3: ...ion Failure to do so may deteriorate the part safety function and or service life In addi tion personal accident machine trouble and or damage to material caused by unauthorized modifications will void 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...

Page 4: ...rs ambu lance service hospital and fire department posted near your telephone 004 E01A 0437 SA 437 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job You may need A hard hat 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 equipm...

Page 5: ...arplugs to protect against objec tionable or uncomfortably loud noises 006 E01A 0434 SA 434 INSPECT MACHINE Inspect your machine carefully each day or shift by walking around it before you start it to avoid per sonal injury In the walk around inspection be sure to cover all points described in the RE START INSPEC TION chapter in the operator s manual 007 E01A 0435 SA 435 ...

Page 6: ...tore them in their specified loca tions Avoid storing transparent bottles in the cab Do not attach any transparent type window decora tions on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flammable objects and or explosives away from the machine ...

Page 7: ...3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut Off Solenoid Valve Group 9 Signal Control Valve Group 10 2 Spool Solenoid Valve Unit Group 11 Engine 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...

Page 8: ... 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others Upperstructure Group 8 Others Undercarriage TECHNICAL MANUAL Troubleshooting SECTION 4 OPERATIONAL PER FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Unit ...

Page 9: ...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 10 Group 3 Painting Painting W1 3 1 Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil Tank W1 4 1 ...

Page 10: ... 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 gea...

Page 11: ...r 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 ...

Page 12: ...der 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 ple...

Page 13: ...re 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 ...

Page 14: ...ep 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 un...

Page 15: ... 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 Separat...

Page 16: ...omponents 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 ...

Page 17: ...unting nut 16 4 24 210 21 155 Cab mounting anchor bolt 20 1 30 550 55 406 13 Cab cushion rubber mounting bolt 12 8 19 110 11 81 6 10 10 1 7 10 17 50 5 37 14 Cover mounting bolt 12 19 90 9 66 Flexible master coupling of piping 1 4 28UNF 11 5 9 0 6 4 15 T bolt clamp of high pressure piping 8 10 6 0 6 4 Upperstructure 18 30 27 390 40 288 16 Swing bearing mounting bolt to Undercarriage 16 36 24 265 27...

Page 18: ...550 55 0 55 13 Cab cushion rubber mounting bolt 12 8 19 110 11 0 11 6 10 8 13 10 17 50 5 1 37 14 Cover mounting bolt 12 19 90 9 2 66 13 10 3 to 12 4 1 05 to 1 26 8 to 9 Flexible master coupling of piping 8 1 4 28UNF 4 pairs 11 6 0 6 4 15 T bolt clamp of high pressure piping 8 10 6 0 6 4 Upperstructure 18 30 27 390 40 0 288 16 Swing bearing mounting bolt to Undercarriage 16 36 24 265 27 0 195 Trave...

Page 19: ...7 091 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 21 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 4...

Page 20: ...m 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 ap plication 5 Make sure that nut and bolt threads are clean before install ing Remove dirt or corrosion if any Bolt Tightening Order When tightening two or more bolts tighten them al ...

Page 21: ...s alternately and di agonally as shown to ensure even tightening 5 Do not use air wrenches Using an air wrench often causes tight ening of one bolt fully before tightening of the others result ing in damage to O rings or un even 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 pin...

Page 22: ... 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 21 5 22 22 39 4 0 28 5 27 27 93 9 5 69 32 32 137 14 0 101 36 36 175 18 0 129 41 ...

Page 23: ...ng 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 leak ing do not re tighten nut 9 Re place O ring 6 with a new one and check that O ring 6 is cor rectly seated in place tighten nut 9 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...

Page 24: ...ds 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 kg 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...

Page 25: ...s hose rup ture 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...

Page 26: ...s or other deterioration and replace as necessary Be sure to perform periodic inspection of all hoses as shown below and replace or retighten any defective parts found as necessary Consult your authorized dealer for correct replace ment Periodic Replacement Parts Replacement Intervals Fuel hose Fuel tank to supply pump Every 2 years Oil filter hose Engine to oil filter Every 2 years Engine Heater ...

Page 27: ...olour Inside and outside surface of cab HG Beige Deep Shaded area on cab Left side only Shining Silver Right window guards U Bolt KANSAI PAINT LF 113 230B Charcoal series black half glossy Suspension lifter N2 0 Black Lever High Grade Black Travel pilot shut off foot rest Engine cover High Grade Black Tool box Tool box cover HG Beige Deep Cover Step HG Beige Deep Handrail on upperstructure right s...

Page 28: ...e should not exceed 70 C when painting and drying Engine Cover Camera Cover Decal TAXI yellow Decal Shining Silver Decal TAXI yellow Tool Box Mirror Stay Tool Box Cover Step Cover Handrail on Upperstructure Right Side Shaded Area Shining Silver A Paint All Circumference in the Hinge Swing Position Shining Silver Panel Align with the Panel Shining Silver Painted Range on Door Shining Silver Section...

Page 29: ...eft side only Shining Silver Right window guards U Bolt KANSAI PAINT LF 113 230B Charcoal series black half glossy Suspension lifter N2 0 Black Lever High Grade Black Travel pilot shut off foot rest Engine cover High Grade Black Tool box Control valve cover HG Beige Deep Handrail on cab left side HG Beige Deep Handrail on upperstructure right side High Grade Black Mirror stay High Grade Black Nons...

Page 30: ...re should not exceed 70 C when painting and drying Engine Cover Camera Cover Decal Shining Silver Mirror Stay Control Valve Cover Handrail on the Cab Left Side A Painted All Circumference in the Hinge Swing Position Shining Silver Shaded Area Shining Silver Panel Align with the Panel Shining Silver Painted Range on Door Shining Silver Section A 10 Door Rear Panel Door Upper Cover on the Swing Devi...

Page 31: ...rnal 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 Push the air bleed valve 1 on the air breather to release any remaining pressure from hydraulic oil tank 3 3 Remove cap 2 of hydraulic oil tank 3 4 Connect a vacuum pump with th...

Page 32: ...lve W2 4 40 Disassembly and Assembly of Gear Pump W2 4 42 Disassembly and Assembly of Gear Pump Optional W2 4 44 Maintenance Standard W2 4 46 Group 5 Control Valve Removal and Installation of Control Valve ZX110 3 class 120 3 class W2 5 1 Removal and Installation of Control Valve ZX135US 3 class W2 5 5 Disassembly of Control Valve 4 Spool Side W2 5 10 Disassembly of Control Valve 5 Spool Side W2 5...

Page 33: ...enoid Valve W2 8 6 Group 9 Signal Control Valve Removal and Installation of Signal Control Valve ZX110 3 class 120 3 class W2 9 1 Removal and Installation of Signal Control Valve ZX135US 3 class W2 9 3 Structure of Signal Control Valve W2 9 8 Group 10 2 Spool Solenoid Valve Unit Removal and Installation of 2 Spool Solenoid Valve Unit ZX110 3 class 120 3 class W2 10 1 Removal and Installation of 2 ...

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