(SRT TO NANTON KH180 Hydraulic Crawler Crane M2004‘This Instruction Manual contains information on the operation, lubrication and maintenance of the Hitachi [ROP Crawler Crane. It also contains a description of the major units and their func tions in relation to other components of the machine. The care you give your Hitachi KH180 Crawler Crane will greately @etermine the longevity of this machine. How well the machine continues to give satisfactory performance depends upon the mainner in which it is operated. It is requested that this manual be read through so that the machine is always in top mechanical condition. For the operation, lubrication and maintenance of the engine, refer to the Engine Operator's Manual published separately for the purpose. Hitachi Construction Machinery Co., Ltd.PROTECTIVE AND SAFETY GUIDEPOINTS ON THE USE OF "VIBRO-HAKMER" ‘Three basic rules Limit the boom angle (and hence the working radius) so that Lift ing capacity will substantially exceed the gross VIBRO-HAMMER weight, In other words, work your crane with some margin of 1ift- ing ability. This can be accomplished by satisfying the follow- ing formula: Rated capacity - gross VIBRO-HAMMER weight* 2 NOTE: *Inclusive of the weights of hock and pile. 2, Make sure that the pile extracting force is always perpendicular. Use @ gantry or similar supporting frame. 3. Suspend the spring-type damper of the hammer with a multi-part cable line ponding from the top of the supporting frame. The VIBRO-NAUMER drives by the force of vibration. Alt neocseary preoautions oten fron thie knowledge. When you start extracting the pile, there's no telling just how much resistance load it will impose on the crane. The golden rule for any cranenan is: "Never try to lift a load that you can~ not estimate." But you have to pull it out the just the same; then the only conceivable solution to this problem is to use an "A" shaped or gantry support frame. ‘Take up the unpredictable resistance load by the two stiff legs of the "AY structure, which props up the boom as shown (see the next page). Have the pedestal of each leg pegged against skiad~ ing, and have the boom hoist line slackened. with this arrange- ment, the force for hoisting the pile from ground through the sprins-type damper and hanner is countered by the "A" frame tope, not by the boom point. Do not exert too much a hoisting force to the damper: there is a Limit to this force for the damper. should you exceed the Linit, the springs would be stretched as far as they can: under this condition, the vibration would directly act on the booms and this force, coupled with that of pile extraction (to constitute 2 complex dynamic load), might cause the cable to fail, force the boom to shake or even fracture the boom lattice at welded joints. The multi-part cable Line, mentioned in Rule 3, should be used also in suspending the hammer from the hook end of the hoist Line.Connecting the hook direct to the lifting Link of the hanmer is a bad practice: a hook so connected could fail due to the vibration. Example of "A" support frame for VIBRO-HAMMER operation ave boon hoist rope Slackened during pile Pile extractor, antinakta Pedsstad With the VIBRO-HAMNER directly suspended from the boom point, it As possible but not advisable to shake the pile (being extracted) sidewise by swinging the boom and exert a large hoisting pull to the pile-a pull of such a magnitude as will float the tail end of the machine. This manner of pile extraction may seem expedient but the gain is imaginary: clutches might overheat and seize or, for worse, the boom might fail. It is a chancy and hazardous method of working. ‘The safe, and therefore the best, method is to use an "A" frame similar to the one illustrated above.conTeNTS SECTION 1. SPECIFICATIONS AND TABULATED DATA 111 BINENSIONS 13 CLAMSHELL SPECIFICATIONS SECTION 2. OPERATION INSTRUCTIONS 21 ARRANGEMENT OF CONTROLS 22 FUNCTIONAL DESCRIPTION OF SWITCHES, INSTRUMENTS AND LAMPS ON THE PANEL 25. CONTROL OPERATION 23.1 Sutiag Up the Ege 232 Load Hoisting 233° Swingag 234 oom Hoisting 236 Crawl Spesing 237 Cambinstaction Operation 235 Control on Hydra Oi Coner 239 Crane Wotk with the Lifting Hook SECTION 3. MAINTENANCE INSTRUCTIONS 3 MAINTENANCE SERVICING INTERVALS, 312 soRou Sering 313 28Dhow,SoDhour nd 1000hoor Sering 3.4 Chain he Suction Filter by Wathog 31.5 Line iter Element Replacement 1 Replacing the Conte Fer Eleent SALT Chaning by Wasting the Hae Ol Tank At Beater 318 Acculator Sing 5.19 Pcie the Machin n Long Outage 32.1 Hydric Ol Checks 322 Cae of Hydeale OF 323 Hydaslc Oi Change 0 n 26 36 »33. DESCRIPTION OF THE MACHINE CONSTRUCTION, AND ADJUSTMENTS 332 Moat Chtsher 322 Holt Bakes 334 Swing Bakes 5.5 Automatic Bordo Bake 336 Tock Tom Adjustment 33.7 Regering of Bolts ané Note 34 LUBRICATING ATTENTIONS 5.5 REPAIR WORK SUGGESTIONS AND THFS SECTION 4, WIRE ROPES 42. CARE OF WIRE ROPES 462. WIRE ROPE REPLACEMENT 43. REEVING 44 STANDARD WIRE ROPE SPECIFICATIONS SECTION S, ASSEMBLY AND DISASSEMBLY OF FRONT ATTACHMENT 5.1 ASSEMBLY AND DISASSEMBLY OF CRANE FRONT 5.1.1 Moun te Crane Boor 51.2 Mounting the Cane Atachment 513 Mounting the 3b Boom 52 CLAMSHELL INSTALLATION 53. IMPORTANT TIPS ON DISASSEMBLY AND ASSEMBLY (OF THE FRONT SECTION 6. TRANSPORTING THE MACHINE (61 TRANSPORTING THE MACHINE BY ITS ONN POWER. 62. TRANSPORTING THE MACHINE ON A TRAILER (63 TRANSPORTING THE MACHINE ON A FREIGHT CAR (64 TRANSPORTING THE MACHINE IN KNOCKDOWN STATE bee a ss se a o n n aSECTION 1, SPECIFICATIONS AND TABULATED DATA, Seal clLifting capacity sooe Boom lent Be 49m Sib length 6% 18m Boor + ib lengths a+i2m 40415 m Prime mover Diese engine Rated output 153 PS Rated rpm 22000 Seed | Rodin [Rema ‘Mn Rook Ro (iow) Sajsminin | 208 | Ropes ‘aa Rook ower (how) Say2smimin | 208 | Rope peed Ta Rook ho (ahlow) s07smjnia | 209 | Rope seed Ta hook ower ihow) Sa7sminia | 209 | Rope eed Swe Sips Boom hae “nia 1p | Roperpeed Tar Gishow) 1/0 8k “Gradebiiy ae ‘Groand prema (O58 glen (with 1m wanda bom)| evga) KHIS0 Crawler Crane Rated Load Cures‘ale 1 KHTIBO Creve rane Rated Loads 6 ‘The loads shown above da not exceed 78% ofthe tipping losd with the unit on frm level ground “The loads shown above include the weight of hook block or bucket. “Tho jib rated load is dents with the main hook rated load, atthe same working radius. Deduct the following valves from the loads shown above when the jib is installed to the boom: 700 ke (when (2m or shorter jib i installed.) 800 kg (when 1S-m jb is installed.) The boom length that permits installation of the ibis 25 to 43 moter, ‘The maximum jib length for 43m boom is 12 meters The weight of the counterweight (comprising thee pieces) 140 tons Be sure to spread the crawlers when using the unit for crane operation,ih sore oun in) ee Wong a) IN Cul Crane Working Ronseable 1.2 Ofte Angles and Maxum Rate Loads re to) Toate see caae | oma | 12mm | IS {withics) oe eed ene io 00 | «00 | 300 | 290 a 400 | 380 [320 | 230 wt) [400 | 330 | 305 | 190 ‘able 12 Number Parts of Rope an Maximum Rated Loads Sr [Tope [Baar [Soar [ee [or | 0 [ee |e Sar [a = “Tble 4. Weight of Hook Blocks and Bakes (oases) “Aitachment oer. ee wi hok | TL ee Le ee cam? tema bucket | 850 om? tomate bucket | S80stony tuo119. CLAMSHELL spECIFICATIONS Ducks capacity Lom?, 081? and 0.6m Boom leet 13% 19m Prime mover Dies engine Rated output 153s Rated tpn 2000 Seed Lo Tia ipnow) | SaaSaiain 209 | Ropeaped ice open ee ee Seng tam [ = Tom at “elas [1h | Rapes ave hatin) | _0ssKee Grol pe OF Gadi 30m Working Rane os) Besa? [aor [a Jo [ar Joe ar J [a Joe Sewiet Taam? | so] | a2] 00] «| a9 [iar{ur| a3[ioolias pieSECTION 2, OPERATION INSTRUCTIONS 2. ARRANGEMENT OF CONTROLS ‘The hand levers, pedals, electial controls and instruments are aranged 1s shown in Fig. 2.1. The swing lock is located on the swing frame atthe lft side of the boom foot. The selector lever forthe crawler expander is located ‘om the forward face of the front dea! axe Fig 2.1 Conrguation of ate Sain, KHIBO22 FUNCTIONAL DESCRIPTION OF SUITCHES, INSTRUMENTS AND LAMRS ON ° oon Gog @ ° a) ay ao) Iastrumets ed Lamps {ater wurmap um of cold eg tn an Fai cacy vt Na wong nse of cae een 7nd bane Nieman enprte ei o eteen 3 a 80% ‘io Sl! nd oe a te pen ee eam or23 pos peop en eine lb ddowe tathe ie (Ginencvon FEUD CURRENT LOT LA Rawr such iio Fa am ir reba f 2 1 60 boon ovenioist ALARM swrrew Before taking his duty position in the cab for work, the opertor is required to make sure that the machine is in operable condition. There are ‘many checks 10 be made by him for this purpose. The following are the very ‘minima; he sould make it his habit to check each before starting the day's work: o ° @ o 3 © o 6 ° 1s oll upto teel in fuel tank, hydraulic ol tank, gear cases, engine ol an, ‘Are hydraute oll and lubricating oil clean? Is the clectialsystom in good condition? Are the instruments working properly? Are engine oil pressure and cooling water temperature up to ‘normal working range (as confirmed on gauges)? ‘Ae all liquid containing parts tight, fee of any’ sign of leakage? ave the safety devices buen tested? Are they found satisfactory? Do all clutches and brakes work propery? ‘Are all hoses in good condition, foe of any surface fays and rubbing signs? Ae all bolts, nuts, unions and other fastening parts tight? ‘Are all wire ropes in good condition? (11) Has the engine been warmed up? ny @ tng || Some RED oy | sin or Coa | 3 | Sion RED ov ‘eam | BACK = Gms w Ravi | a | sips [RED > ov " Taplin | BLACK — Grund w Taewe |? | Sipe > = vetoue | Srare DeSECTION 2, MAINTENANCE INSTRUCTIONS. A wellmaintenanced machine lst long, and its functional parts give full performance at all times, This is particularly true of machines worked under severe duty conditions. The person in charge of the present machine is advised to eed this truism and maintenance it according to the information and instructions which follow: (For engine maintenance, refer to the engine ‘manual) 2.1. MAINTENANCE SERVICING INTERVALS [Except forthe engine, the machine should be serviced at these regular Intervals: (Intervals in houts are based on service meter indication.) (1) Thou servicing very 7 hours, or before starting or after nding the day's work. (Refer to 3.1.1) 2) SOhour servicing Every 50 hours, or once @ week, (3.1.2), G) 28ohour semvicing Every 250 hours. G.1.3) (4) S0Onour servicing very $00 hovrs. 3.13) (8) 1000Hour servicing Every 1000 hours. (3.1.3) 2141 Pheer Seming (Check items are stated in question form, Check and service so that ‘your answer to each wll be positive (1) [soil upto lve in engine oil pan? Is engine coolant up to level? (@) Are clutch and brake linings clean of oil or water? Are the linings in ood condition with respect to lining wear? Are clutches and brakes adjusted properly and free from any sins of malconditon? (©) Are all guid containing parts fee of leakage? (@) Are trick roles, take-up tumblers and drive wheels fre of ol leakage? NOTE: Loosen the plug on each (0 find out if theo lows out, i not, 4 means that the ol is gone and that you should immediately contact the HITACHI service shop to have thelr assistance in emedying this condition. (3) Is the machine properly lubricated at all ubrication points? (6) Areall hoses feo of surface Haws? () Areall bolts, nuts and other fasteners it? Are pipe connections tight?(8) Are all cables in good condition, free of any damage? Is each cotter portion tight? [Alter the day’s work, service the machine as follows (1) Clean the machine, inspect various pats for leekage of water or oi, check belts and nuts for tahtnes. Inspect the machine forthe extent of damage, if any, and take steps (0 have it repaired. (Cleaning the ‘machine before inspecting itis important because a cleaned machine is easier to check and inspect.) (2) Fill up the fuel tank, and record the amount of consumption inthe Jog book. (@) Drain the engine cooling system if freezing temperatures are expected for the outage tine. For the cooling water, se soft water of drinking: water quality, [At intervals of $0 hours, the machine shouldbe serviced, in addition to the T4hour or daily servicing, a follows: (1) After the fist 50 hours, replace the line filter element, Thereafter, the element isto be replaced a intervals of 250 hours (see 3.1.5). 2) Clean the radiator core in order to uphold the cooling efficiency G) Ada distilled water to the css of the battery ifelectolyte levels low. (4) Inspect the eletecal wires for frayed or stripped insulation. Check the terminal connections for tightness. ()_ Adjust the crawler tracks for proper tension, as necessary. (6) Retighten bolts and nuts as necesary (ste 3.3.) (Check te oil evel in each gear box and, a necessary, replenish. 213 z5Dhour,SoOhur and 1000haer Senvicng Every 250 hous, camry out the following serves (1) Replace the fuel filter element (2) Change the engine coolant. (@)_ Replace the line filter element (see 3.1.5) (4) Clean the suction filter, located in the hydraulic oll tank, by washing ‘The method i explained in 3.1.4 (3) Replace tho contol oll cixcuit filter element (ee 3.1.6) (6) Drain off the sediments and condensate water from the fuel tank.(1) Drain off the condensate water from the hydraulic oil tank: (8) Clean by washing the hydraulic oil tank ir breather (2) Retihten bolts and ts very 500 hours, camry out the following services: (1). Flush the radiator clea, using a caustic soda solution 2) Charge make-up nitrogen g3s into the accumulator. The method is Aeseited in 3.1.8, Every 1000 hous, cary out the following services: (1) Replace the two accumulators belonging fo the clutch-bake contrl circuit. Refer 1 3.1.8 (2) Change the hydraulic oil and flush the tan clea, IMPORTANT: The machine should be overhauled at interval of 3000 to 4000 hours, depending on the general condition of the ‘machine as determined by the user in consltation with the HITACHI service shop. ‘314 Cletnng Se Sution Fer by Washing (1) Referring to the cutaway view given below, remove six bolts (1) on the top ofthe hydraulic oil tank, and take out the air breather (2) (2) Insert your hand through the opening, from which the ie breather (2) wis removed, to reach the hand grip of the suction filter (3), and take out the filter. The filter is of metal, and sides off when pulled upward G) Outside of the tank, wath the filter clean. Remove metal particles auering to the manet (4).Q a TES pea @ Dain (Catawayvew ofthe ution ier ad nk 1n any hydraulic drive machine, the qulity of hydraulic i transmitting power from the source to drive components is & very important factor of the durability of the machine. The line fer for mintaiing the oil ‘walty in regard to cleanines, and serves this purpose by its filtering clement. The element i fo be regularly replaced so that the fier is always in best condition. Aller the fst SO hours and at intervals of 250 houts hereafter, replace the filter element a fllows© ® ° ” © © Referring to the cutaway view, loosen plug (1) to admit air into the filter. Loosen plug (6) 10 drain out the oil inside Remove six bolts (7), and take off the cover (), Remove split pin (4) and wing nut (3), and draw out the element (2). Wash the case (8), inner cover (5) td bottom section Install the new element by reversing the foregoing disusembling steps 30 (Cotaway view fn fer)3:18 Replacing the Contotsrout Fata Elma The replacement procedure i 8 follows (1) Referring to the cutaway’ view sven below, remove the drain plug (1) and “0” rng (2), @) Remove four hex-ooosed head bolts (3) and draw off the cover (4). Th elemeat (5) comes out withthe cove. (@)_ Remove the spi pin (6), wing rut (7) and packing (8). Take off the existing element, mount the new element and semble the filter, —-@ (Cotaway view of contact ften{27 Cling by thing the Myra Oi Tank Ar Brenther “The cleaning procedure is as follows (1) Refering to the cut way view, remove four bolts (1 securing the 2 sirbreatherto the tank \ top, and in the breather out of the tank (2) Unserow the breather cap (2) 10 separate it suet from the inside-the- tank ter (4). et (8) Glan the cap (2) and fer (4) by washing The outside the tank ier (3) is intogrl with the cap;do notattempt to remove it from the cap. (4) To wash the filter (4), draw it off the body (6). The oo filters in the breather are of * metal, (Cotaway sew of debra) NOTE: Before stating sir breather removal for cleaning ter replacement, be sure to clean the tank top around the breather in place and aso the breather cap, After taking out the breather assembly, cover up the opening to keep out dust. 2218 Aesumaatr Soi ‘There are two accumulators, one for clutches and one for brakes. Both ave charged with nitrogen gas. The specified gas pressure is 16 kafem? (1) Servicing intervals ‘Alter the fist 6 months oF SOD hours by the service mete, whichever ‘occurs ealer, and aftr the ast 9 months oF 750 hours, whichever occurs eavir, check the ans presure according to the method described iQ) After the frst 12 months or 1000 hours, whichever occurs eatin, replace the accumulator assemble. (©) Gas presure checking method Lr itso Hyde o eee 1) Shut down the engine to stop supplying hydraulic pressure to the sccumulators. Operate the main and auxiliary clutch levers repeatedly to lower the primary pressure at PPC. vate 2) Install he test presture gauge on the fe fitting (1/4) between PC valve and rotary joint. The gauge should be the one calibrated for 0 t0 75 kalem? Gauge.3) Disconnect the secondary-sige pipe from the reducing valve, and serow the blanking plug (3/8) into the valve 4) Startup the engine to run the oi pump. inorder to bud up pressure inthe eluteh accumulator 5) Shut down the engine to interrupt pressure supply. While reading ‘he pressure enuge raged on the tee, slowly loosen the hose “A” at ‘he inlet of PPC. valve to let out the ol. This decreases the presses, rma uns the gauge indication fll gradually. As this process continues, {he | leation will drop suddenly: write down the pressure value at Whit this sudden drop occurs. Now the check for the clutch ac _rlator i completed 6) Install high-pressure rubber hose, 1 meter long, terminated with PT YA male fittings, one at cach end, between the filter and the reducing vale, using a bushing (1/2 x 1/4) and a socket (1/2, both oF high-pressure type 7) At the portion indicated as “B", install the test pressure gnuge, 0 ~ 75 kglem? Gauge. This gnuge may be installed between ‘and reducing valve, instead 8) Startup the engine to build presure in the brake accumulator. 9) Stop the engine. By the method explained in 5), bleed out the oil from the portion “B” and read the pressure gauge just when a sudden drop in pressure occurs. Write down this presture value For the brake accumulator, Compare the two recorded readings against the reference value of 13, kglem, whichis for both clutch and brake. Ifthe readings ate short of the reference value, it means thatthe Nz as in the accumulator isnot enough, tnd that the accumulator needs recharge. The method of charging the gas is described in (3) below: NOTES: 1) The portions “A” and “B" for bleeding out the oil must be In the rubber hose pars (under the operator's seat), To bled out, Joosen the cap nt 2) Two pessons are roqulsed for caning out the foregoing procedure, one for oil bleeding and one for reading the essure gauge.(3). Recharging the accumlators with gas 2 > » 2 o » . ~@ | (Schematic view of schist) Referring to the schematic above, ft adaptor (3) tothe serew (2) provided on the top of accumulator (1). Mount trce-way gis vale (4) on the adaptor, as shown tighten the bleedoff vale (5) in the three-way valve. Install the test pressure sug: (6) on the threo-way valve by running i ito the gauge Using a hose, connect the Ny gas cylinder (8) to the eas supply connection (7) on three-way valve (4). Loosen screw (2) and then tum it counterclockwise about one rotation Crack open the valve (9) on the Nz cylinder to start supplying the a, Watch the gauge indication, When the indication reaches the specif cation value, close valve (9) to interupt the supply and allow the fenuge indiation to sete, After this pause, read the gauge again the indication has dropped even slightly from the specification ‘value, crack open valve (9) ain to charge the gas nif the indication 's noted to have risen above the specification value, bleed the pressure out by opening the blosd-off valve (5), ‘Tighten the screw (2) good and hard, up toa torque of 150 ~ 200 kaon,8) Let out the gas in the hose by opening valve (S), and remove the see-way valve and adaptor from the accumulator. 9) Check the sew port part ofthe accumulator for tightness and make sure that no gus is leaking fom this pat. This check i tobe effected by running "soap water fest” using a brush and soapy water. 19 Maing the Machine Long Oto |A machine placed in ong outage without any provisions for protection often emetges in substantially deteriorated condition from the outage, To void such deterioration, carry out the measures (1) through (5), below, before taking the machine out of service for outage, The ast messure (6) is forthe cae ofthe machine in outage (1), Wash the machine lean; and serie the crawlers thoroughly (2) Relubricate all points acconding to the lubrication chart. Oil exposed ‘metal surfaces, a6 necessary, to protect them aguinst resting (@) Take down the battery, have it recharged and stove it soparataly. (4) Drain the cooling system of the engine, and put on a caution tag reading "no water in engine” (3) Clean up hand tools and store them separately (6) At intervals of one week, run the engin in idling condition for about 'S minute to reestablish oll fs on all running pars. (Be sre to fil ‘up the cooling system before starting the engine and to drain it after the Sainte idling run.) ‘The quality of hydraulic oll has an important beating on the hydraulic performance and the durabiity of hydrauie components of this machine. The fll transmits power at a very high pressure: this fact alone isa suiient reason forthe good maintenance cate needed by the oi 321 Hyrae OW Chucks (1) Checks before starting the engine forthe day's work Check oil level in the hydraulic ol tank, and check the oil temperature If the il level i abnormally low, it means thatthe ols leaking somewhere, possibly from pipe joints or from the working components such as the motor, Never operate the machine with suc oil leakage uncorrected = 36-‘The il tank is equipped with a oll lve gauge having an upper and 4 ower limit mark, There 4s a0 difficulty in determining the proper oil level Before starting to work the machine, make sure the ol temperature & sbove 30°C as read on the femperature gauge: if not, warm up the oil by recirculating it for some time with the engine kept running with «low speed. This measure is usually necessary in cold weather. (@) Checks after starting the engine forthe days work (Check the oll tomperatute, inspect the hydraulic components and lines for evidence of el leakage, and observe the running condition ofthe pumps and motors. The following chart summarizes the nature ofthese checks Waitoaiec | Howeosieck [Grom Purp Hydabo | Rand theo empesare| 30°C - 130 | Fo eatimating the tempersire | page ssn fuged 1 ke or baer gy ae te ol to snd ‘ove BO bt thie emis ‘iestage | Vaaly pec he | NoTeage | For preventing oat various pat and ‘yd and ae Seniporea. ct tutenne pr ‘Toupeatare | Fete tempers |S Toelow | Deetng ses of cotpumps | byputiags ger to fount ct — | shnormal tera sch pomp. fenpeatue | condition Tip ase] Eten nt aad pump [Steady aoe | Detetng th rene forloodet ad pitch farina ope rubbing i be pup ‘Tenpeatus | These as Tor punpa [Toes ator | Detecting ies of sndnose of pea somal intra 322, Core of Hyde OF ‘The hydraulic oi in service isnot permanent; it has to be replaced by 4 new supply after a certain duration of servic. It may deteriorate prema: turely to require renewal before the nomal end of its serviceability isreached, Oil deterioration comes from two sources: entry of foreign matters, patticulaly pity matters into the oi is one; loss of "body" or viscosity is the otter, (1) Enty of foreign matters Before shipment from the factory of the machine, its hydraulic circuits fre thoroughly cleaned by Nushing and then charged with ¢ esh supply of hydraulic oll During the intial operation of the machine, dust is more Hable to enter the circuits, hydeaulic components produce metal particles due to their “weasingin” action, and the ols more subject to oxidation. ‘An oil deteriorated by these causes adversely affects all hydraulic com> ponents, “Machine excursion,” he, # machine getting out of control is an limate result ofthe continued use of such an oi 2) Los of “body” ‘The hydraulic oil constantly kept ator above 80°C in dally operation ‘of the machine wil prematurely ose is viscosity. Such an oll shard on the ‘working components ofthe hydraulic system and can substantially shorten thse ite How tocteck the ol and how to diagnose are summa ‘qulckreference char inthe Following orn nny | WR Saga a aa RT ATE co [osm or | ends tom neat rpg aa compare oct | no] ce ti asm om soe feiniorar | moe inde oe! ane et marta in a Cg 2 hanno, Ctig mad 3i a ooh Tosca Raa [eo ie i ao ee nt] cnga een ft. ah act 325. Hyaulie Of Change Ifa periodical check on the hydraulic oll at any time reveals a badly Aeteriorated condition, change it immediately, even when the scheduled periodical change is ahead in time. Should it become obvious in the course of time that the oll tends to deteriorate prematurely, consult the HITACH. service shop to pinpoint and remedy the use CAUTION: Use only one brand of hydraulic oi. Mixing different brands ‘may result in a harmful oi, The machine is shipped from the factory with its hydraulic system fled with DAPHNE HYDRAULIC FLUID #44 (of IDEMITSU PETROLEUM), To replace this ol by another brand, be sure to flush the entire system clean before filling in the different brand, Be sure the hydraulic oil selected in field meets the oil specification. [Never substiute gear oll, machine oil spindle ol or vegetable: type oil for the hydraulic ol of this machine. “The Model KH180 cravler crane consists of three structures: namely, ‘the emwler unit, the alkaround:swing revolving unit and the font attachment All drive for working the machine is transmitted hydraulieally from the pump unit driven by the engine331 Hyde Tanumisin of Power ‘The source of hydraulic pressure for driving the vatious hydraulic working components & the pump unit directly coupled to the engine. AS shown in Fig, 3.1, each hydraulic circuit is equipped with a relietype safety valve to prevent abnormal rie of pressure in order to protect the hydraulic tines nd components. All reducing gear trains receive lubrication from respective oil baths ‘Hydraulic oll the blood ofthis machine. The oi should be wel cared for by changing it regularly and servicing the iors and others 2s prescribed. [= hee fl | Fg 32 Hydrabe Cuca Digan fr Cute and Brakesveer MHS ORTEN CAL‘The clutches for transmitting drive to the hoisting drums ate of band. ‘ype. The procedure of adjusting the clutch wil be explained by refering to Fig. 34 (1) Move the triangular lever {nto neutral position; dain fut the oilin lute eytinder (Dsand loosen the lock aut securing eich stopper bolt ©. @) Loosen stopper bolts «3) until their heads clear clutch band CD) (3) Tur the cluten to bring band guide (2) to top side (the guide ison bottom side in Fig 34). Adjust set screw (©), which i on the dead fend of the clutch band, in such @ way a 0 produce « learence of about 1mm Fp 34 Hoi Catch ‘between linag and drum. (4) Similarly adjust sot sew (8), which ison the live end, to produce a clearance of about | mm between dram aad lining. (9) Loosen tock aut (7); tum pushrod (6) to reposition it in such a way ‘hat, when the clutch is pushed back, the piston in euteh eyinder (S) will move inward all the way. (6) In order to prevent uneven wear of the lining, center the clutch band to the aus of the drum, This sto be accomplished by tuning stopper bolt (4) when the lever is moved back and held there, At thie time, rake sure that the other stopper bolts are not exerting any force to the band. () Test the clutch, adjusted as above, by operating the clutch contol lever at the contol station. Make sure that, when the lever is pushed back, pushrod (6) and piston move in together, in mutual contact, in retracting direction(8) After verifying the adjustment, tighten the lock nuts. lu the foregoing procedure, be sure 10 have pushrod (6) so adjusted that the top of the piston will not show out ofthe end face of cylinder (). The west limit on clutch band linings is 6 mm. A ining wor to this much thickness must be replaced, “The hoist rake is to be adjusted, afer removal ofits cover, a follows: (1) Retersing to Fig 35, adjust holt (6), roller (8) and stopper (7) in such 4 way that the band-locrum clearance willbe anywhere between 0.8 and 1.O mm, with the brake pedal (1) left in released position, Fg 35 Hote Bake (2) Adjust nut (4) to set the length of the spring to 71.5 mm. Depress the pedal (1) to brake the drum and, under this condition, check to be sure thatthe spring is compressed to 70:mm in length, ()_ Replace the lining if found worn down to 6 mm in thickness ‘The hydraulic pressure for contcolling the clutches and brakes comes ‘rough the unlosder valve: the setting of this valve determines the value of control presure, Turing te adjusting sew on the unloder valve clockwise raise the setting, and vice vera, The unlosder valve is iil Tactoy-st, tnd should not require any readjustment in fel ‘An internally-expanding shoe type brake is used for braking the revolving unit, The brake doubles as parking brake. The adjusting procedure willbe explained by referting to Fig. 3.6.(1) Move the lever (1) into neutral postion, theroby releasing. the brake (Tum adjusting mut (4) inthe iretion of “A” until the shoes ‘ear fly sasist the drum. (3) Tum back (in the direction of "BY the nut (4) by 10 notches. ‘This turing will produce a deur tostioe clearance of 0.25 mm, “The wearlimiton the shoe linings 1s S mm (thickness), Fie 36 Swing Bake 535. Autmae Boom not Bake ‘The following adjusting procedure, referenced to Fig. 3.7, is for the prescribed liningtosdrum clearance at thre places in the automatic brake for the boom hoisting drm (1) Check to be sure tha spring (2, sod (b), nut (€), mut (), mut (), spacer (48) and others are set a8 shown in Fig 3.700). Adjust muts (OMG), if necessary, to produce 50mm between rod and spring set and to set the length of spring (a) to 81 mm, a indicated in Fig. 3.7(b). (2) Make sure the bake cylinder and alts associated parts at in positon, presenting the dimensions shown in Fig. 3.1(¢). The boom hoist lever {is to be in neutral position at his time. 2) Keep the engine running in idling condition. Mote the boom hoist lever into lowering position, with the brake released. Under this condition, the distance between fork end and cylinder should be 107 mm as shown in Fig 3.1) f not, adjust the cylinder to produce this much distance () So that the Mat of the eam will squarely ride on the brake band, as shown in Fig 3,7(2), adjust fork end (0. Next, dspace mvt (c) frm {he position shown in Fig 3.1(c) tothe postion shown in Fig 3.14), ‘This displacement isto lock fork end (0. () Adjust the iningto-drum clearance at places “A”, “BY and “C", The clearance is specified 10 be 0.5mm for the ends of the band but (0.25 mm for the middle part of the band. The latter clearance value(0.25 mm) will result if the adjusting bolt there i turned back by 1/S rotation from its fully (but lightly) serewedsn positon. The places "A", “BY and °C, where adjusting manipulation isto be effected, are Indicated in Fig. 3.7( (6) Move the boom hoist lever to neutrals this will de-pressurize the clinder, so that the brake applies. Under this condition, adjust the length of spring (a) to 106 mm by means of nut (4). Make sure that ‘the cam takes the postion indicated in Fig 3.74), (The brake should be in fully applying condition when spring (a) hes expanded to 106 mm in length; if not, ceadjst the Tiningto-drum clearance to the values stated in (8) above IMPORTANT: When the brake isin released condition (which means that spring (a) i in compressed condition), there must be some clearance between spacer (48) and spring set. Ifthe spacer | baring on the seat, reactive force will act on the brake cylinder mounting bolts: this condition could result in a broken brake cylinder, ‘To take up the extr clearance due tolining wear, carry out the adjustment asin step (5). No other adjustment is neossaty for this purpose. 236 Tick Temon Adlsment ech take-up tumbler is complete with adjusting bolts for use in tension adjustment. The track isin proper tension when is sag between ‘tumbler and next carer roller is about 20 mm. Run in or out the two adjusting bolts equally, and check the positon ofthe bearing by refering fo the frame: matks ae provided for this purpose. After adjusting the tack tension, be sure to lock each adjusting bol 2.27 Revguaing of Ble and Nuts The table below lists the major components whose mounting or securing bos and nuts are to be periodically reightened. Intervals are 50 hours and 250 hous. After the initial SO hous eight all bolts indicated in the SO-hour and 2SOhour columes; thereafter, retighten them it two roups as indicatedvo] Moruvcre [eT a2. [a [ear 1 se A 2 a 7 a] aoa scone) oo z 7 = + [esparmpoa > i s 5 [ines oa = Fase = 7 [exh ae =] 25 [ise z = z >| feomios-amwtiany | [=| 2 it Coerce pend pwns] [0 [ar 3 TT Poe sca om leas S ater ee) | ata ps zs 1 | Po mi wom . 1 Pol ppt mos and pamps . bad 7 Giving too much oil or grease is just as bad as giving too little. Some lubricants sold commercially are poor in quality forthe present machine. With these (a points in mind, give Iubricating attentions to the machine period ieally—by refering to the LUBRICATION SCHEDULE CHART carried at the end of thus subsection and by adhering to the following rules (1) Be sure to have the machine standing on level ground when replenishing rar cases and tanks with il for 250:hour services (2) Change all lubricating ols atthe tun of season, as necesary, replacing the existing ones by those with proper viseosity ratings. This does not spply to the hydraulic ol (3). Wen handing oil and grease, be careful not to smear clutch lining, brake linings and electrical components (4) Oil the link connections in the control linkages of clutches and brakes. Wipe offany drips after olin. Be earful not to wet the linings with il(5) Be sure to lightly grease the flat of the cam and the surface of the brake band in the automatic boomhoist brake. Give small amount ‘of gree tothe pinned connections of this brake in order to prevent these connections from geting rusted: rusty connections interfere ‘with smooth brake control. Refer to Fig. 3.7 for the locations of pinned connections (6), Liberally grease lage slevetype bearings. Where grease nipples are ‘provided, pump in grese until old grese oozes out of the bush, (7) Some brands of grease are usable only in a narrow temperature range ‘while others are usable in a wider range. Be sure to select the one which neither “lows” at high temperatures nor “clots” at freezing temperatures, and is Hit to grease gua charging (8) Cleanliness is important. Have the lubricant handling tools eean, Before putting the grease gun 0 2 nipple, clean the nipple thoroughly (9) It is a good practice to give grease lightly to such sliding pats as pinned fork connections, which ae not equipped with nipples. (10) Never allow different brands of lubricant to mix, in or out of the machine. (11), Wire ropes come as impregnated with ol. The impregnation is effected uring manufacture for the purpose of rope protection aginst rsting and wear In order to extend service life of the wite ropes used in the machine, it is necessary to oil them periodically. Fig. 3.9 ilustrates ‘three methods of oiling the rope; the oll should be of penetrating 'ype normally available as a “composition oi” for use on wine ropes. Ar g.39 ting the Cable (12), Before oiling the propel chains, be sure to clean them by wiping off ai. (13). Give wast ol to the lnk pins in the crawler tracks at proper intervals ~s0-(18) When greasing the internal teeth ofthe ring gsar of the evolving uni be sure to turn the unit in smal steps to cover the whole circle (13). Clean the sliding surfaces of tack frame and side frame before gesting. (16) The lubication feature onthe bull wheels, take-up tumblers and track rollers such that these members do not requite periodical lubricating tention. A specal tool is required for charging il into the internal cavity around the shaft, which is normally fled with of Should i leakage be discovered on any ofthese members, contact the HITACHI service shop. The special tool is three-piece set, and is available from HITACHI; when ordering for this tool set, be sure to quote the following putt numbers: Part number Past a 108s) Nozzle 1 417426 Fitting 1 954963 Micronoe 1 LUBRICATION SCHEDULE CHART Taimeereon | GO| a8 ec aaa 2 Seager | GO| ait | eck = onto mar [Ga =izes [gpm fe es SES Bae [= [RSH coma carmen ei | Sita | Sake | oe | Ett (as = eae hie 2415 REPAIR VIORK SUGGESTIONS ANO HPS (1) Some of the hydraulic system components are not meant for dis ‘sembly in fled. They ae: oil pumps, control valves, counterbalance valves, brake valves and oil motors. Never attempt to change the setting ofthe reli vale built inthe control valve: if ay maleondition 's suspected of this rele valve, contact HITACHI for advice. (@) Disssembly and reassembly of any component must be caried out with the parts lst book on hand. Refer constantly tothe book (@) For the replacement pars, use those available from or specified by HITACHI, Common bolts available in the market must not be sub- stituted for those used in mounting or securing hydraulic components including pipes. Special high-strength bolts are wsed for these com ponents because they are subject to extremely lage stresses, (4) Securing or mounting bolt for hydraulic components must be tightened to proper torque values based on bolt size. This is because these ‘components have to resist high reactive forces during operation. The tightening-torque schedule for the securing and mounting bolts used In this machine 5 follows: Bolt sce Gamvaiad [6 [ 8 [10] 12 [14 [ve] | 20 [7 Forue en) | | [ao}rol pe fastas [ar (5) When handling & hydraulic component or part, be careful not to score its joint or mating faces, and exercise caution not to allow any dust particles or foreign matters to enter it 1) Before reinstalling pipes, hoses and tanks or reservoir, be sure to wash them clet, 2) Examine each "O” sing closely before fiting it in place. Never wwe scored or otherwise damaged “O" ring. Make sure that the groove for admiting each "0" sng is smooth 3) Some of pipes and hoses are temminated with threaded ends for serewin connection. Before inning the ‘headed end in, wrap the dreaded portion with a sealing tape, leaving. one oF two Seu pe formost threads exposed, at shown in the lustration. Use the sealing tape sparingly OM" mn erpbut adequately to ensure tightness. 4) Be careful not to twist any high-pressure hose when connecting it ‘Twisted high-pressure hoses will not last long, (6) When ofdering for replacement pats, be sure to quote the part umber indicated in the pats list book, -SECTION 4, WIRE ROPES 41° CARE OF mine ROPES Power for handling the load, be it an object hitched to the lifting hook ‘ora bulk of materia Being hugged in ‘Owough the deck machinory on the revolving unit and is trnsmitted through 4 cable tne, The cable is @ power transmitting member: its quality and the care if recsives have 2 great deal to do with the working efficieney of the ‘machine. Here lies the reason why the use of high-arade wire ropes mecting the HITACHI specifications i insisted upon forthe cable lines of the present machine the bucket, comes fiom the engine ‘The fundamentals ofthe proper care of cables areas follows (1) Refersing to Fig. 4.1, a wire rope is made up of sts! wires wound into iam ch ere) strands, and the strands are wound eS e acount venerorcorenichmay gy he be another strand of miniature @_% 83 cable). A rope consisting of 6 strands, each strand consisting of" paecoemge LW L098 29 steel wires is called a 6329 wire Fig.l Wire Rope Contin rope. The center strand or core may be a manila rope, which is more common: if iti a wire rope, then a, the whole is ale an Independent ~ Wire Rope Core (LW.R.C.) cable. comtateg nt a ‘Cables used in construction machin- 7 (fe (2) Cables are supplied in coils, usually a coting in order to reve them in trading sieved / FEY & in uncling iecton, so that the 4 33 cable wil extend stright witht a & Aeveloping any twist oF loops, = Which are Hale to kink. Fig, 4.2 Pg. 42. Whe Rope Unciing° » 2 * iustrate instances of proper and improper unsoling methods. How to wind the rope forthe fist tne Insert the rope end into the hitching pocket provided in the drum, !nd hook the end inside. Make sure the rope is tenminated within the rum, without showing the end out ofthe pocket. Refer to Fig. 43, eS FE 43 Hitchin the Wie Rope othe ram Spool the rope around the drum by running the drum, keeping the suceesve tur of rope to one sie, that is esinst the drum Mange Use a hammer, as necessary, to “lead” the incoming rope. See Fis, 4.40). Make the first wrap of rope, Keeping the rope in proper tension and leading each turn neatly, so that the wrap will spread squarely tothe other ange, a5 shown in Fig. 4.4(), Just as the second wrap begins, drive the rope into the elesrance and lead it along te flange to Form the fist tun ofthe new wrap a shown, in Fig, 480). Repeat the foregoing process, leading the incoming rope back and forth to for neat wraps fee of eearances between any two adjacent rope tums. Never allow the rope to spool in disorderly manner, The frst spooling correctly carried out will “break it form neat wraps in subsequent winding operations. New wire ropes ate hard break In: for this eason it may be necessary {0 repeat the procedure until the ope becomas fully “broken in.” * the wire rope to = 56