HITACHI ZAXIS 75US Excavator Full Service Repair Manual

Technical Manual (Operational Principle) Vol No.: TO197E-00

INTRODUCTION IN-01 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. • 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 us- age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog • Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material MANUAL COMPOSITION • This manual consists of three portions: the Techni- cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- ual. • Information included in the Technical Manual (Operational Principle): technical information needed for redeliver and delivery, operation and activation of all devices and systems. • Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • 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 assem- ble/disassemble procedures. PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1 -3 -5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual

INTRODUCTION IN-02 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 potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for 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 component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts. • CAUTION: 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. UNITS USED • SI Units (International System of Units) are used in this manual. MKS system units and English units are also indicated in parenthheses just behind SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees. Quantity To Convert From Into Multiply By Pressure MPa kgf/cm 2 10.197 MPa psi 145.0 Power kW PS 1.360 kW HP 1.341 Temperature °C °F °C×1.8+32 Velocity km/h mph 0.6214 min -1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 Quantity To Convert From Into Multiply By Length mm in 0.03937 mm ft 0.003281 L US gal 0.2642 Volume L US qt 1.057 m 3 yd 3 1.308 Weight 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

197T-1-1 SECTION 1 GENERAL CONTENTS Group 1 Specifications Specifications ........................................... T1-1-1 Working Ranges and Machine Transportation Dimensions ..................... T1-1-3 Component Specification .......................... T1-1-5 Group 2 Component Layout Main Components .................................... T1-2-1 Electrical System (Overall System) ........... T1-2-2 Electrical System (Monitor and Switches) ........................... T1-2-4 Others ...................................................... T1-2-6

197T-1-2 (Blank)

GENERAL / Specifications T1-1-1 SPECIFICATIONS M197-12-002 Model EX75UR -5 Front-End Attachment Type − Offset Type Bucket Capacity (Heaped) − PCSA: 0.28 m 3 (0.37 yd 3 ), CECE: 0.25 m 3 Operating Weight kg (lb) 8000 (17600) Basic Machine Weight kg (lb) 6150 (13600) Engine − ISUZU A-4JG1 40.5 kW / 1900 min -1 (55 PS / 1900 rpm) A: Overall Width mm (ft in) 2300 (7’ 7”) B: Cab Height mm (ft in) 2720 (8’ 11”) C: Rear End Swing Radius mm (ft in) 1150 (3’ 9”) D: Minimum Ground Clearance mm (ft in) 405 (1’ 4”) E: Counterweight Clearance mm (ft in) 805 (2’ 7”) F: Engine Cover Height mm (ft in) 1760 (5’ 9”) G: Undercarriage Length mm (ft in) 2960 (9’ 9”) H: Undercarriage Width mm (ft in) 2320 (7’ 7”) I: Sprocket Center to Idler Center mm (ft in) 2290 (7’ 6”) J: Track Shoe Width mm (ft in) 450 (1’ 6”) (Pad Crawler) Ground Pressure kPa (kgf/cm 2 , psi) 34.5 (0.35, 5.0) Swing Speed min -1 (rpm) 10 Travel Speed (Fast/Slow) km/h (mph) 4.5/2.9 (2.8/1.8) Gradeability Degree (%) 35 (70) J J B D E F C I A H G

GENERAL / Specifications T1-1-2 M197-12-005 Model EX75US -5 Front-End Attachment Type − 1.6 m Arm Bucket Capacity (Heaped) − PCSA: 0.28 m 3 (0.37 yd 3 ), CECE: 0.25 m 3 Operating Weight kg (lb) 7000 (15400) Basic Machine Weight kg (lb) 5650 (12500) Engine − ISUZU A-4JG1 40.5 kW / 1900 min -1 (55 PS / 1900 rpm) A: Overall Width mm (ft in) 2300 (7’ 7”) B: Cab Height mm (ft in) 2720 (8’ 11”) C: Rear End Swing Radius mm (ft in) 1150 (3’ 9”) D: Minimum Ground Clearance mm (ft in) 355 ∗ (1’ 2”) E: Counterweight Clearance mm (ft in) 805 ∗ (2’ 6”) F: Engine Cover Height mm (ft in) 1730 ∗ (5’ 8”) G: Undercarriage Length mm (ft in) 2920 (9’ 7”) H: Undercarriage Width mm (ft in) 2320 (7’ 7”) I: Sprocket Center to Idler Center mm (ft in) 2290 (7’ 6”) J: Track Shoe Width mm (ft in) 450 (1’ 6”) (Grouser Shoe) Ground Pressure kPa (kgf/cm 2 , psi) 30.4 (0.31, 4.4) Swing Speed min -1 (rpm) 10 Travel Speed (Fast/Slow) km/h (mph) 4.5/2.9 (2.8/1.8) Gradeability Degree (%) 35 (70) NOTE: Dimensions marked don’t include the shoe lug height. J J G I F E C H D B A

GENERAL / Specifications T1-1-3 WORKING RANGES AND MACHINE TRANSPORTATION DIMENSIONS M197-12-003 M197-12-004 Item Category 1.75 m Arm A: Maximum Digging Reach mm (ft in) 6430 (21’ 1”) B: Maximum Digging Depth mm (ft in) 4230 (13’ 11”) C: Maximum Cutting Height mm (ft in) 7420 (24’ 4”) D: Maximum Dumping Height mm (ft in) 5320 (17’ 5”) E: Overall Transport Height mm (ft in) 2720 (8’ 11”) F: Overall Transport Length mm (ft in) 6040 (19’ 10”) G: Minimum Swing Radius of Front-End Attachment mm (ft in) 1160 (3’ 10”) H: Blade Bottom Highest Position mm (ft in) 450 (1’ 6”) I: Blade Bottom Lowest Position mm (ft in) 230 (9”) J: Maximum Offset mm (ft in) (From the front-end attachment center) Left (Cab Side): 1100 (3’7”) Right: 1050 (3’ 5”) K: Maximum Approach Angle Degree 31° D C B A G F I H K E J J

GENERAL / Specifications T1-1-4 M197-12-006 Item Category 1.62 m Arm A: Maximum Digging Reach mm (ft in) 6540 (21’ 5”) B: Maximum Digging Depth mm (ft in) 4600 ∗ (15’ 1”) C: Maximum Cutting Height mm (ft in) 7250 ∗ (23’ 9”) D: Maximum Dumping Height mm (ft in) 5170 ∗ (17’ 0”) E: Overall Transport Height mm (ft in) 2730 (8’ 11”) F: Overall Transport Length mm (ft in) 6020 (19’ 9”) G: Minimum Swing Radius of Front-End Attachment mm (ft in) 1670 (5’ 6”) NOTE: Dimensions marked ∗ don’t include the shoe lug height. E F B C D G A

GENERAL / Specifications T1-1-5 COMPONENT SPECIFICATION Engine MAIN SPECIFICATION Manufacturer .................................................... ISUZU Model No. ......................................................... 4JG1 Type ................................................................. Diesel, 4 cycle, water-cooled, in-line direct injection type Cyl. No. – bore × stroke .................................... 4-95.4 mm×107 mm (3.76 in×4.21 in) Piston displacement ......................................... 3059 cm 3 (187 in 3 ) Rated output ..................................................... 39 kW/1900 min -1 (53 PS/1900 rpm) Compression ratio ............................................ 18.6 Dry weight ........................................................ 248 kg (546 lb) Firing order ....................................................... 1-3-4-2 Rotation direction.............................................. Clockwise (viewed from fan side) COOLING SYSTEM Cooling fan ....................................................... Dia. 430 mm (17 in) E type, 10 blades, draw-in type Fan pulley speed ratio ...................................... Engine rpm×1.07 Thermostat ....................................................... Cracking temp. at atmospheric pressure: 82 °C (180 F°) Full open tem: 95 °C (203 F°) Water pump ...................................................... Centrifugal type, belt driven LUBRICATION SYSTEM Lubrication pump type ...................................... Trochoid pump Oil filter ............................................................. Full-flow paper element type STARTING SYSTEM Motor ................................................................ Reduction type Voltage ⋅ Output ................................................ 24 V ⋅ 3.2 kW PREHEAT SYSTEM Type ................................................................. Glow plug (24V-25sec) ENGINE STOP SYSTEM Type ................................................................. Fuel shut-off ALTERNATOR Type ................................................................. AC (with IC regulator) Voltage ⋅ Current ............................................... 24 V ⋅ 30 A FUEL SYSTEM Type ................................................................. BOSCH A-type Governor .......................................................... Centrifugal all speed control type Injection nozzle ................................................. Multi-hole nozzle PERFORMANCE Lubrication oil consumption .............................. Less than 20 mL/hr (New engine, at rated output) Fuel consumption ratio ..................................... Less than 238 g/kW/h (175 g/PS/h) (New engine, at rated output) Injection timing ................................................. 13 ° before T.D.C Max. output torque ............................................ 201 N⋅ m (20.5 kgf ⋅ m, 148 lbf ⋅ ft) or more at 1600 min -1 Injection pressure ............................................. 18.1 MPa(150 kgf/cm 2 , 2133 psi) Compression pressure...................................... 2.94 MPa(30 kgf/cm 2 , 427 psi) @ 250 min -1 Valve clearance (inlet/outlet) ............................. 0.4/0.4 mm (when cool) No load speed ................................................. Min: 1000 +50 –0 min -1 , Max.: 2090±25 min -1

HITACHI ZAXIS 75US Excavator Full Service Repair Manual

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