Hitachi ZX170W-5A Workshop Manual Download Page 3

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INTRODUCTION

IN-01

To The Reader

Additional References

Manual Composition

Page Number

This manual is written for an experienced technician to

provide technical information needed to maintain and

repair this machine.

The machine specification and description according to

destination may be explained on this manual.



Be sure to thoroughly read this manual for correct

product information and service procedures.

Please refer to the other materials (operator’s manual,

parts catalog, engine technical material and Hitachi

training material etc.) in addition to this manual.

This manual consists the Technical Manual, the Workshop

Manual and the Engine Manual.



Information included in the Technical Manual:

Technical information needed for redelivery and delivery,

operation and activation of all devices and systems,

operational performance tests, and troubleshooting

procedures.

Each page has a number, located on the center lower part

of the page, and each number contains the following

information:

Example:



Technical Manual: T 1-3-5

Technical Manual

Section Number

Group Number

Consecutive Page Number for Each Group



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 manual. (Note: Do not tear off

the form. Copy it for usage.):



Technical Information Center Hitachi Construction

Machinery Co., Ltd.



TEL: 81-29-832-7084



FAX: 81-29-831-1162



E-mail: [email protected]



Information included in the Workshop Manual:

Technical information needed for maintenance and

repair of the machine, tools and devices needed for

maintenance and repair, maintenance standards, and

removal / installation and assemble / disassemble

procedures.



Information included in the Engine Manual:

Technical information needed for redelivery and delivery

and maintenance and repair of the machine, operation

and activation of all devices and systems, troubleshooting

and assemble / disassemble procedures.



Workshop Manual: W 1-3-2-5

Workshop Manual

Section Number

Group Number

Sub Group Number

Consecutive Page Number for Each Group

WLBJE0-EN-00

Summary of Contents for ZX170W-5A

Page 1: ...l consists of the following separate Part No Technical Manual Operational Principle Vol No TOLBJE0 EN Technical Manual Troubleshooting Vol No TTLBJE0 EN Workshop Manual Vol No WLBJE0 EN Engine Manual Vol No ETDCY EN EWDCY EN WLBJE0 EN 00 PART NO Wheeled Excavator Workshop Manual URL http www hitachi c m com ...

Page 2: ......

Page 3: ...lowing information Example Technical Manual T 1 3 5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group 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 manual Note Do not tear off the form Copy it for usage Technical Information...

Page 4: ...tion which if not conformed to the instructions could result in damage to the machine fNOTE Indicates supplementary technical information or know how Units Used Quantity To Convert From Into Multiply By Length mm in 0 03937 mm ft 0 003281 Volume L US gal 0 2642 L US qt 1 057 m3 yd3 1 308 Weight kg lb 2 205 Force N kgf 0 10197 N lbf 0 2248 Torque N m kgf m 0 10197 Pressure MPa kgf cm2 10 197 MPa ps...

Page 5: ...and Asia and becomes the factual global standards of the mobile telephone GPS Global Positioning System Global positioning system CAN Controller Area Network CAN communication CAN is a serial communications protocol internationally standardized by ISO International Organization for Standardization A C Air Conditioner Air conditioner OP OPT Option Optional component MPDr Maintenance Pro Dr MPDr is ...

Page 6: ...SYMBOL AND ABBREVIATION SY 2 Blank WLBJE0 EN 00 ...

Page 7: ...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 do not use any of the designated signal words above after the safety ...

Page 8: ...ut authorization Failure to do so may deteriorate the part safety function and or service life In addition 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 th...

Page 9: ...ency numbers for doctors ambulance service hospital and fire department posted near your telephone 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 10: ...s or earplugs to protect against objectionable or uncomfortably loud noises 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 Inspect Machine Daily Before Starting section in the operator s manual SA 434 WLBJE0 EN 00 ...

Page 11: ...control shut off lever or control levers which may result in serious injury or death Avoid storing transparent bottles in the cab Do not attach any transparent type window decorations 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 obje...

Page 12: ...epair the damage to the steps and or handrails Retighten loose bolts Never get on and off the machine with tools in your hands 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 depre...

Page 13: ...ever to the LOCK position and put the brake switch in the P parking brake position Turn the key switch OFF to stop the engine Before leaving the machine close all windows doors and access covers and lock them 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 i...

Page 14: ...the cab door windows doors and covers are securely locked Check the mirrors and the monitor in the CAB for problems If there is replace the problem part s or clean the mirror camera and the monitor Refer to Rear View Monitor section on the cleaning of the camera and the monitor Operate Only from Operator s Seat Inappropriate engine starting procedures may cause the machine to runaway possibly resu...

Page 15: ...en the engine starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine Keep Riders off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine Only the operator should be on the machine Keep riders off Riders a...

Page 16: ...f operation and machine movement Do not permit persons other than the operator to enter areas where there is danger such as flying objects Always beware of the surroundings while operating When working in a small area surrounded by obstacles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear side Take care not to sw...

Page 17: ...ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before starting...

Page 18: ...the ground first using large pieces of steel plates strong and firm enough to easily support the machine Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes Prevent machine tipping over from occurring When operating on rough terrain or on slopes Reduce the engine speed Select slow travel speed mode Operate the machine slowly and be cautious wi...

Page 19: ...signal person to coordinate the job site Make sure that all personnel obey the signal person s directions Confirm Direction of Machine to Be Driven Incorrect steering wheel F N R lever operation may result in serious injury or death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the ma...

Page 20: ... to 1 0 m A above the ground If the machine starts to skid or becomes unstable immediately lower the bucket to the ground and stop Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover If the direction must be changed move the machine to level ground then change the direction to ensure safe operation Avoid swinging the upperstructure on slopes Never at...

Page 21: ...ff lever to LOCK position 5 Place F N R lever in the neutral and put the brake switch in the P parking brake position 6 Turn the auto idle switch off 7 Run the engine at slow idle speed without load for 5 minutes to cool down the engine 8 Stop the engine and remove the key from the key switch 9 Block both tires and lower the bucket to the ground Thrust the bucket teeth into the ground if you must ...

Page 22: ...ANDERS BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regulations when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job...

Page 23: ...ADMISSION sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area Check that all personnel or obstacles other than the signal person are not present in the working area before operating the machine Never Position Bucket Over Anyone Never lift move or swing bucket above anyone or a truck cab Serious injury or machine damage may result due...

Page 24: ...SULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT 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 Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping...

Page 25: ...nes and water lines If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury Contact your local diggers hot line if available in your area and or the utility companies directly Have them mark all underground utilities Operate with Caution If the front attachment or any other part of the machine hits against an overhead obstacle such a...

Page 26: ... strike the machine If lightning comes close immediately stop the operation and take the following action When you are around the machine or operating cab less machine evacuate to a safe place far away from the machine When you are in the cab stay in the cab until lightning has passed and safety is secured Close the cab doors and windows Lower the bucket to the ground and stop the engine Put your ...

Page 27: ...enly Keep all persons well away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall Protect Against Flying Debris If flying debris hit eyes or any other part of the body serious injury m...

Page 28: ...ll access doors and compartments 11 Secure the wheels with wedges 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 Always stop the engine before refueling the machine Fill the fuel tank outdoors All...

Page 29: ...e with the travel mode switch 5 Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp 6 Never steer the machine while on the ramp If the traveling direction must be changed while the ramp unload the machine from the ramp reposition the machine on the ground then try loading again 7 At the top end of the ramp where it m...

Page 30: ...roof vent and cab door 10 Lock all access doors and compartments 11 Secure the wheels with wedges If a maintenance procedure must be performed with the engine running do not leave the machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Inspect certain parts periodically and r...

Page 31: ...y work on the machine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer 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 Do not support ...

Page 32: ...feet clothing jewelry and hair do not become entangled when working around rotating parts Prevent Parts from Flying Travel reduction gears are under pressure As pieces may fly off be sure to keep body and face away from AIR RELEASE PLUG to avoid injury GEAR OIL is hot Wait for GEAR OIL to cool then gradually loosen AIR RELEASE PLUG to release pressure SA 344 WLBJE0 EN 00 ...

Page 33: ...ot attempt to mount a tire unless you have the proper equipment and experience to perform the job Have it done by your authorized dealer or a qualified repair service Always maintain the correct tire pressure DO NOT inflate tire above the recommended pressure When inflating tires use a chip on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the ti...

Page 34: ...nd hydraulic oil also become hot during operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool before starting any maintenance or inspection work 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 ...

Page 35: ...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 Tighten repair or replace any missing loose or damaged clamps lines hoses oil cooler and oil cooler flange bolts Do not bend or strike high pressure lines Never install bent or damaged lines pipes or hoses Replace fuel hoses and hydraulic hoses...

Page 36: ...such as dead leaves from entering However flammable materials which have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammable materials Check Key Switch If a fire breaks out failure to stop the engine will escalate the fire hampering fire fighting Always check key switch function before operating the machine every day 1 S...

Page 37: ...nt window can not be opened break the front or rear window panes with the emergency evacuation hammer to escape from the cab Refer to the explanation pages on the Emergency Evacuation Method Beware of Exhaust Fumes Prevent asphyxiation Engine exhaust fumes can cause sickness or death If you must operate in a building be sure there is adequate ventilation Either use an exhaust pipe extension to rem...

Page 38: ...nel should perform welding Never allow an unqualified person to perform welding Turn the battery disconnect switch to the OFF position before performing welding on the machine Grinding on the machine may create fire hazards Store flammable materials in a safe place before starting grinding After finishing welding and grinding recheck that there are no abnormalities such as the area surrounding the...

Page 39: ... Lines Containing Flammable Fluids Do not weld or flame cut pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precautions for Handling Accumulator and Gas Damper High pressure nitrogen gas is sealed in the accumulator and the gas damper Inappropriate handling may cause explosion possibly resulting in serious injury or ...

Page 40: ...sbestos and Silicon Dust and Other Contamination Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust or other contamination may cause sickness Depending on the work site conditions the risk of inhaling asbestos fiber silicon dust or other contamination may exist Spray water to prevent asbestos fibers silico...

Page 41: ...s Securely tighten all terminals Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire Battery electrolyte is poisonous If the battery should explode battery electrolyte may be splashed into eyes possibly resulting in blindness Be sure to wear eye protection when checking electrolyte specific gravity Service Air Conditioning System Safe...

Page 42: ...emical products used with your machine Dispose of Waste Properly 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 Do...

Page 43: ...ngerous 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 WLBJE0 EN 00 ...

Page 44: ...s This machine is equipped with a communication terminal type A or type B Consult your nearest authorized dealer for the type of communication terminal Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipments Type A Type B E GSM900 0 573 W kg 914 8 MHz 0 12 W kg 897 6 MHz DCS 1800 0 130 W kg 1710 2 MHz 0 06 W kg 1748 0 MHz WCDMA Band I 0 271 W kg 1950 0 MHz 0 05 ...

Page 45: ...amage or fire on the machine and the communication terminal Before removing or installing the communication terminal consult your authorized Hitachi dealer Do not pinch or forcibly pull cables cords and connectors Failure to do so may cause damage or fire on the machine and the communication terminal due to short broken circuit WLBJE0 EN 00 ...

Page 46: ...d dealer before welding parts or drilling a hole on the cab which possibly reduces the cab strength Be sure to always fasten the seat belt when operating the machine If the machine rolls over without operator fastening the seat belt the operator may become injured may be thrown out from the cab and or may become crushed under the machine even though the cab has the protective structure The ROPS ce...

Page 47: ...recautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 3 Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Engine Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Valve Group 12 Solenoid Valv...

Page 48: ...WLBJE0 EN 00 ...

Page 49: ...mation available at the time of publication The right is reserved to make changes at any time without notice SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Transmission Group 5 Axle Group 6 Axle Lock Cylinder Group 7 Operate Check Valve Group 8 Solenoid Valve Group 9 Propeller Shaft Group 10 Cylinder SECTION 5 FRONT ATTACHMENT Group 1 Front Attachm...

Page 50: ...WLBJE0 EN 00 ...

Page 51: ...Air from Hydraulic System W1 4 1 1 Bleeding Air from Fuel System W1 4 1 2 Bleeding Air from Transmission W1 4 1 4 Bleeding Air from Brake Axle W1 4 1 7 Group 5 Preparation Preparation before Inspection and Maintenance W1 5 1 1 Hydraulic Circuit Pressure Release Procedure W1 5 1 3 Pressure Release from Hydraulic Oil Tank W1 5 1 4 Pressure Release from Expansion Tank W1 5 1 5 Pressure Release from B...

Page 52: ...LBJE0W 1 2 Blank WLBJE0 EN 00 ...

Page 53: ...r draining fluids Use matching marks for easier reassembling if necessary Be sure to use the specified special tools when instructed If a part or component cannot be removed after removing its securing nuts and bolts do not attempt to remove it forcibly Find the cause s and then take the appropriate measures to remove it Orderly arrange disassembled parts Mark and tag them if necessary Store commo...

Page 54: ...ing seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that it is instal...

Page 55: ...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 under the load t...

Page 56: ...ing for any damage corresponding to following examples 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 a a a e f b b c c g d a Broken Sewing Thread a Broken Sewing Thread e Separation of Belt b Scuffing f Scoring b Scuffing c Fuzz d Broken Sewing Thread c Fuzz g Broken Warp a Broken Sewing Thread W162 01 01 002 W16...

Page 57: ...Allowable errors will be indicated if necessary Allowable Limit 1 Normal machine performance cannot be accomplished after exceeding this limit 2 Repair or adjustment is difficult after exceeding this limit 3 Repair or adjustment is impossible after exceeding this limit Therefore in consideration of operation efficiency and maintenance expense proper maintenance shall be carried out before reaching...

Page 58: ...Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1 1 1 6 Blank WLBJE0 EN 00 ...

Page 59: ...omponents Specified Tightening Torque Chart 2013 09 Bolt Dia mm Hexagon Head Bolt Socket Bolt Wrench Size mm Socket Bolt Wrench Size mm N m lbf ft N m lbf ft N m lbf ft N m lbf ft 6 3 to 4 2 2 to 3 10 5 8 30 22 20 15 10 7 4 13 20 15 6 10 65 48 50 37 20 15 17 50 37 8 12 110 81 90 66 35 26 19 90 66 10 14 180 133 140 103 55 41 22 140 103 12 16 270 200 210 155 80 59 24 210 155 14 18 400 300 300 220 12...

Page 60: ... bolt hole Also the bolts that are too short cannot develop sufficient tightening force The torque given in the chart on the previous page are for general use only however a different torque is given for a specific application Use the specified torque Clean the nut and bolt threads and remove dirt or corrosion before installing Tightening Order When tightening two or more bolts tighten them altern...

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