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Hitachi EX1900-5 Excavator Technical Workshop Manual – PDF Download
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Hitachi EX1900-5 Excavator Technical Workshop Manual
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Description
Hitachi EX1900-5 Excavator Technical Workshop Manual
File Details:
Hitachi EX1900-5 Excavator Technical Workshop Manual
- Manual Language:English
- Pages: 518
- Size: 7.78 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX1900-5 EXCAVATOR TECHNICAL WORKSHOP MANUAL – PDF DOWNLOAD:
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Description:
Hitachi EX1900-5 Excavator Technical Workshop Manual
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.
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 Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• 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 assemble/ disassemble procedures.
Table of Contents:
Hitachi EX1900-5 Excavator Technical Workshop Manual
INTRODUCTION................................................................... 1 SAFETY......................................................................... 3 ALL CONTENTS................................................................... 29 SECTION 1 GENERAL INFORMATION.................................................. 31 GROUP 1 Precautions for Disassembling and Assembling....................... 33 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING.......................... 33 MAINTENANCE STANDARD TERMINOLOGY....................................... 39 GROUP 2 Tightening......................................................... 41 TIGHTENING TORQUE SPECIFICATION........................................ 41 TORQUE CHART........................................................... 43 PIPING JOINT........................................................... 46 PERIODIC REPLACEMENT OF PARTS.......................................... 50 GROUP 3 Bleeding Air from Hydraulic Oil Tank............................... 51 BLEEDING AIR FROM HYDRAULIC OIL TANK.................................. 51 VACUUM................................................................. 52 SECTION 2 UPPERSTRUCTURE....................................................... 55 GROUP 1 Cab................................................................ 57 DIMENSIONS OF THE CAB GLASS............................................ 57 GROUP 2 Counterweight...................................................... 59 REMOVE AND INSTALL COUNTER-WEIGHT...................................... 59 GROUP 3 Main Frame......................................................... 63 REMOVE AND INSTALL MAIN FRAME.......................................... 63 GROUP 4 Pump Device........................................................ 69 REMOVE AND INSTALL PUMP DEVICE......................................... 69 DISASSEMBLE PUMP TRANSMISSION.......................................... 90 ASSEMBLE PUMP TRANSMISSION............................................. 94 DISASSEMBLE MAIN PUMP.................................................. 98 ASSEMBLE MAIN PUMP.....................................................106 MAINTENANCE STANDARD...................................................114 DISASSEMBLE REGULATOR FOR MAIN PUMP...................................116 ASSEMBLE REGULATOR FOR MAIN PUMP......................................122 COMPONENTS OF 4-SPOOL PUMP.............................................129 DISASSEMBLE OIL COOLER FAN DRIVE PUMP..................................130 ASSEMBLE OIL COOLER FAN DRIVE PUMP.....................................134 MAINTENANCE STANDARD...................................................140 ASSEMBLE REGULATOR FOR OIL COOLER FAN DRIVE PUMP......................148 DISASSEMBLE AIR COMPRESSOR DRIVE PUMP AND PILOT PUMP..................154 ASSEMBLE AIR COMPRESSOR DRIVE PUMP AND PILOT PUMP.....................160 MAINTENANCE STANDARD...................................................164 DISASSEMBLE LUBRICATION PUMP FOR PUMP TRANSMISSION....................166 ASSEMBLE LUBRICATION PUMP FOR PUMP TRANSMISSION.......................168 MAINTENANCE STANDARD...................................................170 GROUP 5 Control Valve......................................................171 REMOVE AND INSTALL CONTROL VALVE.......................................171 PILOT PORT LOCATION....................................................173 ASSEMBLE CONTORL VALVE.................................................182 DISASSEMBLE AND ASSEMBLE MAIN RELIEF VALVE, OVERLOAD RELIEF VALVE....186 MAKE-UP VALVE CONSTRUCTION.............................................188 GROUP 6 Swing Device.......................................................189 REMOVE AND INSTALL SWING DEVICE........................................189 DISASSEMBLE SWING REDUCTION GEAR......................................192 ASSEMBLE SWING REDUCTION GEAR..........................................200 DISASSEMBLE SWING MOTOR................................................210 ASSEMBLE SWING MOTOR...................................................214 MAINTENANCE STANDARD...................................................218 DISASSEMBLE AND ASSEMBLE VALVE UNIT...................................220 GROUP 7 Pilot Valve........................................................223 REMOVE AND INSTALL FRONT / SWING PILOT VALVE 1.......................223 REMOVE AND INSTALL TRAVEL AND BUCKET OPEN / CLOSE PILOT VALVE.........225 PILOT LINE CONNECTION..................................................228 DISASSEMBLE FRONT / SWING PILOT VALVE.................................230 ASSEMBLE FRONT / SWING PILOT VALVE.....................................232 DISASSEMBLE TRAVEL BUCKET OPEN / CLOSE PILOT VALVE....................236 ASSEMBLE TRAVEL BUCKET OPEN / CLOSE PILOT VALVE.......................238 GROUP 8 Pilot Shut-Off Valve...............................................241 REMOVE AND INSTALL PILOT SHUT-OFF VALVE................................241 DISASSEMBLE PILOT SHUT-OFF VALVE.......................................242 ASSEMBLE PILOT SHUT-OFF VALVE..........................................244 GROUP 9 Shuttle Valve......................................................247 REMOVE AND INSTALL SHUTTLE VALVE.......................................247 DISASSEMBLE AND ASSEMBLE SHUTTLE VALVE................................249 GROUP 10 Shockless Valve...................................................251 REMOVE AND INSTALL FRONT ATTACHMENT SHOCKLESS VALVE...................251 THE SHOCKLESS VALVE CONSTRUCYION.......................................252 GROUP 11 Solenoid Valve....................................................253 REMOVE AND INSTALL SOLENOID VALVE......................................253 SOLENOID VALVE CONSTRUCTION............................................254 GROUP 12 Oil Cooler Fan Motor..............................................257 REMOVE AND INSTALL OIL COOLER FAN MOTOR................................257 DISASSEMBLE OIL COOLER FAN MOTOR.......................................262 ASSEMBLE OIL COOLER FAN MOTOR..........................................264 MAINTENANCE STANDARD...................................................266 GROUP 13 Compressor Drive Motor............................................267 REMOVE AND INSTALL COMPRESSOR DRIVE MOTOR..............................267 DISASSEMBLE COMPRESSOR DRIVE MOTOR....................................270 ASSEMBLE COMPRESSOR DRIVE MOTOR.......................................272 GROUP 14 Air Conditioner...................................................275 WORK AFTER REPLACING COMPONENT.........................................275 ADD COMPRESSOR OIL.....................................................275 CHARGE AIR CONDITIONER WITH REFRIGERANT...............................276 GROUP 15 Grease Pump.......................................................285 GREASE PUMP CONSTRUCTION...............................................285 SECTION 3 UNDERCARRIAGE........................................................291 GROUP 1 Swing Bearing......................................................293 REMOVE AND INSTALL SWING BEARING.......................................293 GROUP 2 Travel Device......................................................295 REMOVE AND INSTALL TRAVEL DEVICE.......................................295 DISASSEMBLE TRAVEL REDUCTION GEAR......................................300 ASSEMBLE TRAVEL REDUCTION GEAR.........................................312 DISASSEMBLE TRAVEL MOTOR...............................................324 ASSEMBLE TRAVEL MOTOR..................................................330 MAINTENANCE STANDARD...................................................336 DISASSEMBLE AND ASSEMBLE TRAVEL SPEED MODE SELECTOR VALVE.............338 GROUP 3 Travel Brake Valve.................................................341 REMOVE AND INSTALL TRAVEL BRAKE VALVE.................................341 DISASSEMBLE TRAVEL BRAKE VALVE.........................................344 ASSEMBLE TRAVEL BRAKE VALVE............................................346 GROUP 4 Center Joint.......................................................349 REMOVE AND INSTALL CENTER JOINT........................................349 DISASSEMBLE CENTER JOINT...............................................352 ASSEMBLE CENTER JOINT..................................................354 GROUP 5 Adjuster Cylinder..................................................357 REMOVE AND INSTALL ADJUSTER CYLINDER...................................357 DISASSEMBLE ADJUSTER CYLINDER..........................................362 ASSEMBLE ADJUSTER CYLINDER.............................................364 GROUP 6 Front Idler........................................................367 REMOVE AND INSTALL FRONT IDLER.........................................367 DISASSEMBLE FRONT IDLER................................................370 ASSEMBLE FRONT IDLER...................................................372 MAITENANCE STANDARD....................................................374 GROUP 7 Upper and Lower Roller.............................................375 REMOVE AND INSTALL UPPER/LOWER ROLLER.................................375 DISASSEMBLE UPPER ROLLER...............................................380 ASSEMBLE UPPER ROLLER..................................................382 DISASSEMBLE LOWER ROLLER...............................................384 ASSEMBLE LOWER ROLLER..................................................386 MAINTENANCE STANDARD...................................................388 GROUP 8 Track Shoes........................................................391 REMOVE AND INSTALL TRACK SHOES.........................................391 TRACK SHOES CONSTRUCTION...............................................395 MAINTENANCE STANDARD...................................................396 GROUP 9 Accumulator........................................................397 REMOVE AND INSTALL ACCUMULATOR.........................................397 DISASSEMBLE ACCUMULATOR................................................400 ASSEMBLE ACCUMULATOR...................................................402 GROUP 10 Welding Repair Procedure..........................................407 WELDING REPAIR PROCEDURE...............................................407 WELDING ROD SPECIFICATION..............................................408 REPAIR TRACK SHOE......................................................409 REPAIR FRONT IDLER.....................................................412 REPAIR SPROCKET........................................................414 SECTION 4 FRONT ATTACHMENT.....................................................419 GROUP 1 Front Attachment...................................................421 REMOVE AND INSTALL FRONT ATTACHMENT....................................421 GROUP 2 Cylinder...........................................................451 REMOVE AND INSTALL CYLINDER............................................451 DISASSEMBLE CYLINDER...................................................483 ASSEMBLE CYLINDER......................................................492 MAIN POINTS TO BLEED AIR...............................................498 MAINTENANCE STANDARD...................................................500 GROUP 3 Bushing and Point..................................................503 REMOVE AND INSTALL BUSHING.............................................503 MAINTENANCE STANDARD...................................................506 REVISION REQUEST FORM..........................................................517 PATTERN LIST...................................................................518
Please Note:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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