PDF Workshop Manual Hitachi ZX65USB-5A Hydraulic Excavator - 1 MB
This complete workshop manual for the Hitachi ZX65USB-5A Hydraulic Excavator is an essential tool for any technician.
It contains detailed repair and service procedures, specifications, and troubleshooting charts.
From the engine to the hydraulic system, every component is covered with step-by-step instructions.
This manual empowers you to perform everything from routine service to major overhauls with confidence and precision.
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--- Page 1 ---
PART NO. WAFA-EN-00
ZX65USB-5A
HYDRAULIC EXCAVATOR
Workshop Manual
ZX65USB-5A
WORKSHOP MANUAL
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
WAFA-EN-00
Service Manual consists of the following separate Part No.
Technical Manual : Vol. No.TAFA-EN
Workshop Manual : Vol. No.WAFA-EN
PRINTED IN JAPAN (K) 2013, 11 Engine Manual : Vol. No.ETADB-EN, EWADB-EN
--- Page 3 ---
SAFETY
General Precautions for Cab
Always keep inside the cab clean by observing instructions
below, to prevent any personal accidents from occurring.
Before entering the cab, thoroughly remove all dirt
and/or oil such as mud, grease, soil or stones that may
mess up the cab 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 resulting
in a personal accident.
Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot 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 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. If the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
Use Handrails and Steps
Falling is one of the major causes of personal injury.
When you get on and off the machine, always use the
crawler instead of the step for safety. Also get on and off
from the position of the crawler that can secure your feet
space enough.
When you get on and off the machine, always face the
machine.
Maintain a three-point contact with the steps and
handrails.
Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
In case adhered slippery material such as oil, grease, SA-439
or mud is present on steps, handrails, or platforms,
thoroughly remove such material.
SA-5
--- Page 4 ---
SAFETY
Avoid Injury From Back-over and Swing
Accidents
If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN SA-383
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 signal person and operator.
Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
Keep windows, mirrors, and lights clean and in good
condition.
Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
Read and understand all operating instructions in the
operator’s manual.
SA-384
SA-15
--- Page 5 ---
SAFETY
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 with stays
or blocks strong enough to support the machine and/or
attachment weight.
SA-527
Stay Clear of Moving Parts
Contact with moving parts can cause serious injury or death
due to amputation or entanglement.
To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
SA-2294
SA-25
--- Page 6 ---
SAFETY
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, electrolyte,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct procedures
and use recommended equipment.
See your authorized dealer for MSDS.
SA-309
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 battery.
When draining fluid, use a leakproof container with a
capacity larger than the drained fluid volume to receive it.
Do not pour waste onto the ground, down a drain, or into
any water source.
Inquire on the proper way to dispose of harmful waste
such as oil, fuel, coolant, brake fluid, filters, and battery
from your local environmental or recycling center.
SA-226
SA-35
--- Page 7 ---
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings a
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. W102-04-02-016
Take care not to allow the sling to become wet. The
a- Correct Eyehole Lifting
load may slip.
Method
When required to use more than one sling, use slings
with the same width and length to keep the lifted b
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 W105-04-01-008
with protrusions.
Avoid dragging slings on the ground, throwing b- Incorrect Eyehole Lifting
Method
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 that they won’t
deteriorate with heat, sun light, or chemicals.
c W162-01-01-009
c- Bent of Sling
W1-1-1-3
--- Page 8 ---
SECTION 1 GENERAL
Group 2 Tightening
Quick Coupling
3 1
1. Coupling procedure
Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
Cap the removed hoses using special plug.
dCAUTION:
When disconnecting, do not damage joint
surface.
When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
W1-2-1-7
--- Page 9 ---
SECTION 1 GENERAL
Group 5 Releasing Pressure
Releasing Pressure in Hydraulic Circuit
Release any remaining pressure in the following
procedures when removing and installing the front
attachment.
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
2. Tilt up the floor. (Refer to the operator’s manual.)
dCAUTION: Each attachment may move rapidly in
case the overload relief valve is loosened rapidly.
Check that the machine has set in the position for
inspection and maintenance and loosen it slowly.
Do not loosen it more than 3/4 turns as hydraulic 6 1
oil may spout.
IMPORTANT: Do not turn lock nut (8) and adjusting 5 2
screw (9). If turning, the setting changes.
3. Slowly loosen body (7) of the overload relief valve in 4
which any remaining pressure will be released. 3
j : 24 mm
m : 70 to 80 N·m (7 to 8 kgf·m, 52 to 59 lbf·ft)
T1N0-03-04-003
1- Overload Relief Valve (Boom 4- Overload Relief Valve (Bucket
Lower) Roll-In)
2- Overload Relief Valve (Arm 5- Overload Relief Valve (Arm
Roll-Out) Roll-In)
3- Overload Relief Valve (Bucket 6- Overload Relief Valve (Boom
Roll-Out) Raise)
7 8
9
TAEA-03-04-013
7- Body 9 - Adjusting Screw
8- Lock Nut
W1-5-1-1
--- Page 10 ---
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Swing Motor
1
2
WADB-03-07-002
1- Rotor 2- Plunger (9 Used)
W2-1-2-1
--- Page 11 ---
SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage
Track
Rubber Crawler Crack 1 4
1. Outside of Rubber Crawler
If there is a crack on lug base (1) with depth of 3 mm 5
2
(0.12 in) or more, repair the track.
If there is a crack between lugs (2) with depth of 3
mm (0.12 in) or more, repair the track. 3
If there is a crack on lugs (3) or between lugs (2) and
it reaches steel code (5) or steel core (4) with length
of 30 mm (1.18 in) or more, immediately repair the W190-03-07-001
track.
2. Inside of Rubber Crawler (Roller (6) Side) 4
If there is a crack that reaches steel code (5) or steel
core (4), immediately repair the track.
5
W190-03-07-002
Lug Wear
1. If height (A) of lug (8) is less than 5 mm (0.2 in), 6
replace rubber crawler (7) as an assembly.
2. If any part of steel code (5) appeared on the track, 7
replace the worn rubber crawler as an assembly.
A
W190-03-07-003
8
5
W190-03-07-004
W2-2-4-1
--- Page 12 ---
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Disassembly of Pilot Valves for Boom Swing, Blade,
Removal and Installation of Cab...............................W3-1-1-1 Auxiliary (Optional)...................................................W3-8-8-1
Dimensions of Cab Glass..............................................W3-1-2-1 Assembly of Pilot Valves for Boom Swing, Blade,
Auxiliary (Optional) . ................................................W3-8-8-4
Group 2 Counterweight Disassembly of Blade Pilot Valve (Optional)..........W3-8-9-1
Removal and Installation of Counterweight.........W3-2-1-1 Assembly of Blade Pilot Valve (Optional)...............W3-8-9-4
Group 5 Pump Device Group 9 Solenoid Valve
Removal and Installation of Pump Device.............W3-5-1-1 Removal and Installation of 2-Spool
Disassembly of Pump Device.....................................W3-5-2-1 Solenoid Valve............................................................W3-9-1-1
Assembly of Pump Device...........................................W3-5-2-5 Disassembly of 2-Spool Solenoid Valve..................W3-9-2-1
Disassembly of Regulator............................................W3-5-3-1 Assembly of 2-Spool Solenoid Valve........................W3-9-2-3
Assembly of Regulator..................................................W3-5-3-3
Group 10 Revolution Sensing Valve
Group 6 Control Valve Removal and Installation of Revolution
Removal and Installation of Control Valve.............W3-6-1-1 Sensing Valve........................................................... W3-10-1-1
Disassembly and Assembly of Control Valve........W3-6-2-1 Disassembly of Revolution Sensing Valve........... W3-10-2-1
Disassembly of Body......................................................W3-6-3-1 Assembly of Revolution Sensing Valve................ W3-10-2-3
Assembly of Body...........................................................W3-6-3-7
Disassembly of Unload Section.................................W3-6-4-1 Group 11 Auxiliary Flow Rate Selector Valve
Assembly of Unload Section.......................................W3-6-4-3 Removal and Installation of Auxiliary
Disassembly of Boom Anti-Drift Valve.....................W3-6-5-1 Flow Rate Selector Valve (OP)............................ W3-11-1-1
Assembly of Boom Anti-Drift Valve..........................W3-6-5-3 Disassembly of Auxiliary Flow Rate
Disassembly of Spool....................................................W3-6-6-1 Selector Valve (OP)................................................. W3-11-2-1
Assembly of Spool..........................................................W3-6-6-3 Assembly of Auxiliary Flow Rate
Disassembly of Shuttle Valve and Selector Valve (OP)................................................. W3-11-2-3
Pressure Compensator............................................W3-6-7-1
Assembly of Shuttle Valve and
Pressure Compensator ...........................................W3-6-7-3
Group 7 Swing Device
Removal and Installation of Swing Device............W3-7-1-1
Disassembly of Swing Device.....................................W3-7-2-1
Assembly of Swing Device..........................................W3-7-2-3
Disassembly of Swing Motor......................................W3-7-3-1
Assembly of Swing Motor............................................W3-7-3-4
Group 8 Pilot Valve
Removal and Installation of Pilot Valve (Left).......W3-8-1-1
Removal and Installation of Pilot Valve (Right)....W3-8-2-1
Removal and Installation of Travel Pilot Valve......W3-8-3-1
Removal and Installation of Blade Pilot Valve......W3-8-4-1
Removal and Installation of Boom
Swing Pilot Valve........................................................W3-8-5-1
Disassembly of Pilot Valves (Right and Left).........W3-8-6-1
Assembly of Pilot Valves (Right and Left)...............W3-8-6-4
Disassembly of Travel Pilot Valve...............................W3-8-7-1
Assembly of Travel Pilot Valve....................................W3-8-7-5
AFAW-3-1
--- Page 13 ---
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Unit: mm
WAFA-03-01-001
WAFA-03-01-002
a- Mark Position b- Black Ceramic Coating
Surface
W3-1-2-5
--- Page 14 ---
SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight
Removal and Installation of Counterweight
7 1 2
8, 9
6 5 4 3
WAFA-03-02-001 WAFA-03-02-002
Removal
1. Set the machine position for inspection and 5. Remove bolt, washer (1) and bolts, washers (7) (5
maintenance. (Refer to W1-6-1.) used). Remove cover (2).
2. Tilt the cab assembly to the front side. (Refer to the j : 17 mm
operator’s manual.)
6. Remove bolts (8) (2 used) and washers (9) (2 used).
3. Remove bolts, washers (4) (3 used) and bolts,
washers (6) (2 used). Remove cover (5). j : 24 mm
j : 17 mm
4. Open cover (3).
W3-2-1-1
--- Page 15 ---
SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device
Disassembly of Pump Device
1 2 12
3
4
5 13
6 7
8
9 14
10
11
26 15
25
16
24
23
22
21
27 17
28 18
29
30
29
31 19
20
32
33
34
35
36 38
37 39
40
41
42
54 43
41
44
45
46
53 47
48
49
52
50
51
W1N0-02-03-051
W3-5-2-1
--- Page 16 ---
SECTION 3 UPPERSTRUCTURE
Group 5 Pump Device
Disassembly of Regulator
1
2
3
43 4
44 5
45
46 6
47 7
8
9
48 8
49 10
30
50 11
31
32 51
52
33 53
34 54
55
56
35
36
37
38 12 12
29 39 13 13
40 14 15
41
42
16
28
27
26
25
24 18
23 19
20 17
21
22
W1N0-02-03-061
1- Spool 15- Orifice 29- Socket Bolt (2 Used) 43- Adjusting Screw Kit
2- Sleeve 16- Valve Body 30- Nut 44- O-Ring
3- Connector 17- Lever 31- Adjusting Screw 45- Spring Seat
4- Spring 18- Retainer 32- Nut 46- Spring
5- Needle Roller 19- Spring Washer 33- Adjusting Screw 47- Spool
6- Retainer 20- Socket Bolt 34- Cover 48- Sleeve
7- O-Ring 21- O-Ring 35- O-Ring 49- O-Ring
8- Backup Ring (2 Used) 22- Plug 36- Spring Guide 50- O-Ring (2 Used)
9- O-Ring (2 Used) 23- Plug 37- O-Ring 51- Backup Ring
10- Plug 24- O-Ring 38- Spring Guide 52- O-Ring
11- Retaining Ring 25- Stopper 39- Spring 53- O-Ring
12- Plug (2 Used) 26- Spring 40- Spring 54- Backup Ring
13- O-Ring (2 Used) 27- Steel Ball 41- Spring Seat 55- Spring
14- Orifice 28- Valve Seat 42- O-Ring 56- Spring Seat
W3-5-3-1
--- Page 17 ---
SECTION 3 UPPERSTRUCTURE
Group 6 Control Valve
Disassembly and Assembly of Control Valve
94
95
96
A
B
C
D
E