Hitachi EX 2600-6 Instruction manual

SAFETY
SA-1
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 in-
jury.
 Follow recommended precautions and safe operating
practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS
On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
 DANGER indicates an imminently hazardous situa-
tion which, if not avoided, will result in death or seri-
ous injury.
 WARNING 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 designated
signal words above after the safety alert symbol are
occasionally used on this machine.
CAUTION also calls attention to safety messages in this
manual.
To avoid 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.
NOTE indicates an additional explanation for an
element of information.
002-E01A-1223
SA-1223

SAFETY
SA-2
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine
and all safety messages in the operators manual.
Safety signs should be installed, maintained and re-
placed when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).
Learn how to operate the machine and its controls cor-
rectly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.
 Unauthorized modifications of the machine may im-
pair its function and/or safety and affect machine life.
The safety messages in this SAFETY chapter are in-
tended 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 operat-
ing or performing maintenance work on the machine.
003-E01B-0003
SA-003
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.
 To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
 Establish emergency procedure guidelines to cope
with fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.
004-E01A-0437
SA-437

SAFETY
SA-3
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appro-
priate 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 equipment and clothing for
the job. 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 headphones
while operating the machine.
005-E01A-0438
SA-438
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.
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 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.
007-E01A-0435 SA-435

SAFETY
SA-4
GENERAL PRECAUTIONS FOR CAB
 Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operators work boots
the operators foot may slip off the pedal, possibly re-
sulting in a personal accident.
 Do not leave parts and/or tools lying around the op-
erators seat. Store them in their specified locations.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possi-
bly 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.
 After using the ashtray, always cover it to extinguish
the match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.
524-E01A-0000

SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleed Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 DQR Valve
Group 7 Shuttle Valve
Group 8 8-Spool Solenoid Valve Unit
Group 9 Oil Cooler Fan Motor
Group 10 Compressor Drive Motor
Group 11 Air Conditioner
Group 12 Lift Cylinder (Fast-Filling System)
Group 13 Lift Cylinder
(Sliding Fold-In Ladder)
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Travel Brake Valve
Group 4 Drive Tumbler
Group 5 Center Joint
Group 6 Adjuster Cylinder
Group 7 Front Idler
Group 8 Upper and Lower Roller
Group 9 Track
Group 10 Accumulator
Group 11 Welding Repair Procedure
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point

TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ELU System
Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Control Equipment
Group 5 DQR Valve
Group 6 Travel Device
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 General
Group 2 Cross Reference Table
Group 3 Component Layout
Group 4 Troubleshooting A
Group 5 Troubleshooting B
Group 6 Troubleshooting C
Group 7 Electrical System Inspection

KBAW-1-1
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology......... W1-1-7
Group 2 Tightening
Tightening Torque Specification ............... 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

GENERAL / Precautions for Disassembling and Assembling
W1-1-1
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
 The machine model, machine serial number, and
hour meter reading.
 Reason for disassembly (symptoms, failed parts,
and causes).
 Clogging of filters and oil, water or air leaks, if
any.
 Capacities and 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 gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling.
 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),
then take the appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and
tag them as necessary.
 Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
 Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
 Measure and record the degree of wear and
clearances.

GENERAL / Precautions for Disassembling and Assembling
W1-1-2
Precautions for Assembling
 Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
 Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
 Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
 Be sure that liquid-gasket-applied surfaces are
clean and dry.
 If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
 Utilize matching marks when assembling.
 Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
 Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
Bleeding Air 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 operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump
 Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
 After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
 Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
 After bleeding all the air, securely tighten the
plug.
Bleeding Air from Travel Motor / Swing Motor
 With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

GENERAL / Precautions for Disassembling and Assembling
W1-1-3
Bleeding Air from Hydraulic Circuit
 After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under 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-
plenish oil as necessary.
T142-05-03-007
T142-05-03-008

GENERAL / Precautions for Disassembling and Assembling
W1-1-4
Floating Seal Precautions
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set
with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.
(3) Check O-ring (B) for tears, breaks,
deformation or hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure 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 installed correctly on the seal ring.
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal
mating face (C) by measuring the distances
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating.
W105-03-05-019
W105-03-05-020
W110-03-05-004
a b
b b
aa
a=b
C
A
B
Incorrect Correct
Incorrect
Correct
A
B

GENERAL / Precautions for Disassembling and Assembling
W1-1-5
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. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
 Do not lift acid or alkali chemicals.
 Take care not to allow the sling to become wet.
The load may slip.
 When required to use more than one sling, use
slings with the same width and length to keep 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 under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
 Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
 When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
 Store the nylon slings indoors so they wont dete-
riorate with heat, sun light, or chemicals.
W102-04-02-016
W105-04-01-008
W162-01-01-009
Correct Eyehole
Lifting Method
Incorrect Eyehole
Lifting Method
Bent Sling

GENERAL / Precautions for Disassembling and Assembling
W1-1-6
CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
2. Before using a nylon sling, visually check 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
Separation of
Belt
Broken Sewing
Thread
Scuffing
Scoring
Broken Warp
Fuzz

GENERAL / Precautions for Disassembling and Assembling
W1-1-7
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
2. Dimension of new components 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.

GENERAL / Tightening
W1-2-1
TIGHTENING TORQUE SPECIFICATION
Torque
No. Descriptions Bolt Dia
mm Qty Wrench Size (mm) N m (kgf m)(lbf ft)
1 Engine cushion rubber mounting bolt 36 6 55 3200 (320) (2360)
2 Engine bracket mounting bolt a
b
c
30
UNC3/4
22
12
16
6
46
28.6
32
1450
450
750
(145)
(45)
(75)
(1070)
(330)
(550)
3 Hydraulic oil tank mounting bolt 30 10 46 1450 (145) (1070)
4 Fuel tank mounting bolt 30 16 46 1450 (145) (1070)
5 Pump transmission mounting bolt UNC1/2 16 19 120 (12) (90)
6 Pump device mounting bolt 24 12 36 700 (70) (520)
7 Fan drive pump mounting socket bolt 20 4 17 550 (55) (410)
8 Gear pump mounting bolt 12 4 19 90 (9) (66)
9 Control valve mounting nut 20 12 30 400 (40) (295)
10 Swing device mounting bolt 33 50 50 2600 (260) (1920)
11 Swing motor mounting nut 20 16 30 400 (40) (295)
12 Battery mounting bolt 10 16 17 50 (5) (37)
13 Cab mounting bolt 18 10 27 300 (30) (220)
14 Cab bed mounting bolt 16 42 24 210 (21) (155)
15 Swing bearing mounting bolt 48 60 75 5000 (500) (3700)
16 Counterweight mounting nut 48 6 75 5000 (500) (3700)
17 Engine bed mounting bolt 30 30 46 1450 (145) (1070)
18 Oil cooler mounting nut 24 6 36 700 (70) (520)
19 Radiator mounting nut 27 4 41 1400 (140) (1030)
20 Fan motor bracket mounting bolt 12 12 19 90 (9) (66)
21 Travel device mounting bolt 27
36
20
16
24
56
30
32
41
55
30
24
1400
3200
400
210
(140)
(320)
(40)
(21)
(1030)
(2360)
(295)
(155)
22 Travel motor mounting bolt 22 8 32 750 (75) (550)
23 Upper roller mounting bolt 22 24 32 550 (55) (410)
24 Lower roller mounting bolt 36 64 55 3200 (320) (2360)
25 Track pin-retaining bolt 30 156 46 1950 (195) (1440)
26 Side frame mounting bolt 48 68 75 5000 (500) (3700)
27 Front pin-retaining bolt 24
20
16
28
16
6
36
30
24
700
400
270
(70)
(40)
(27)
(520)
(295)
(200)
28 Stairway beam bolt 22 16 32 750 (75) (550)
29 Stairway bolt 20 16 30 550 (55) (410)

GENERAL / Tightening
W1-2-2
NOTE 1. Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and
nuts to reduce friction coefficient of
them.
2. Make sure bolt and nut threads are
clean before installing.

GENERAL / Tightening
W1-2-3
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or compo-
nents.
SA-040
Specified Tightening Torque Chart
M552-07-091
Socket Bolt
M552-07-090 M157-07-225
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)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

GENERAL / Tightening
W1-2-4
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom 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-
ternately, as shown, to ensure even tightening.
W105-01-01-003
1
6
4
2
3
Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally
1st to 4th
2nd to 3rd
13 11 10
14
12
7
6 1 4
3 2 58
9
5

GENERAL / Tightening
W1-2-5
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts 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 pins. Match the
holes in the bolt and nut while tight-
ening, not while loosening.
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
W105-01-01-015
W105-01-01-016
W105-01-01-008
W105-01-01-009
W105-01-01-010
Bend along edge sharply Do not bend it round
Bend along edge sharply
Loosen
Tighten
WR
O
N
G
RIGHT RIGHT
RIGHT
WR
O
N
G
WR
O
N
G
RIGHT WR
O
N
G
WR
O
N
G
RIGHT
RIGHT