Hitachi ZX690LCH-7, ZX690LCR-7 Hydraulic Excavator WJBQ40-EN-00 (Preview)
WJBQ40-EN-00(1)(20200624)
WJBQ40-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbol and Abbreviation
CONTRASTING LIST OF PART NAME
Contrasting List of Part Name between Technical Manual and Parts Catalog
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handrail and Steps
Adjust the Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Start the Engine Only from Operator’s Seat
Jump Starting
Keep Riders off Machine
Precautions for Operations
Perform Job Site Risk Assessment Beforehand
Install OPG Guard
Restriction of Attachment Installation
Provide Signals for Jobs Involving Multiple Machines
Confirm Direction of Machine Travel
Drive Machine Safely
Avoid Injury from Rollaway Accidents
Avoid Accidents from Reversing and Swing Operation
Keep People Clear from Working Area
Never Position the Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Caution with an Overhead Obstacle
Avoid Power Lines
Precautions for Lightning
Object Handling
Protect Against Flying Debris and Falling Object
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Maintenance Safely
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Avoid Injury from Attachment Falling Accident
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Check for Oil Leaks:
Check for Short circuits:
Clean up Flammable Materials:
Check Key Switch:
Check Heat Shields:
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes on Aftertreatment Device
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection by Operator’s Station when the Machine Rolls Over
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
Precautions for Disassembling and Assembling
Precautions for Disassembling and Assembling
Precautions for Using Floating Seal
Precautions for Using Nylon Sling
Maintenance Standard Terminology
Tightening
Tightening Bolts and Nuts
Bolt Types
Specified Tightening Torque Chart
Tightening Order
Precautions for Spilt Flange
Nut and Bolt Locking
Tightening Piping Joint
Union Joint
Pipe Joint
O-Ring Face Seal Joint
Quick Coupling
Screw-In Connection
Seal Tape Application
Low-Pressure-Hose Clamp Tightening
Connecting Hose
Painting
Painting
Bleeding Air
Bleeding Air from Hydraulic System
Bleeding Air from Main Pump and Fan Pump
Bleeding Air from Travel Motor, Swing Motor
Bleeding Air from Hydraulic Circuit
Bleeding Air from Fuel System
Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping
Preparation
Preparation before Inspection and Maintenance
Hydraulic Circuit Pressure Release Procedure
Pressure Release from Hydraulic Oil Tank
Pressure Release from Expansion Tank
MAINTENANCE STANDARD
Upperstructure
Maintenance Standard for Main Pump
Maintenance Standard for Fan Pump
Maintenance Standard for Swing Motor
Undercarriage
Maintenance Standard for Travel Motor
Maintenance Standard for Sprocket
Maintenance Standard for Center Joint
Maintenance Standard for Front Idler
Maintenance Standard for Upper Roller
Maintenance Standard for Lower Roller
Maintenance Standard for Track
Front Attachment
Maintenance Standard for Pin and Bushing
Maintenance Standard for Side Cutter (4435856, 4435857)
Maintenance Standard for Point (4255718)
Standard Dimensions for Arm and Bucket Connection
Standard Dimensions for Arm and Boom Connection
Maintenance Standard for Cylinder
WJBQ40-EN-00(2)(20200624)
UPPERSTRUCTURE
Cab
Removal of Cab Interior Parts
Removal of Cab Exterior Parts
Removal of Cab Body
Removal of Controller Assembly and Parts Around the Monitor
Installation of Controller Assembly and Parts Around the Monitor
Installation of Cab Body
Installation of Cab Exterior Parts
Installation of Cab Interior Parts
Dimensions of Cab Glass
Procedure to Remove Cab Glass
Procedure to Install Cab Glass
Procedures to Install Upper Door Glass
Procedures to Install Upper Front Glass
Counterweight
Removal of Counterweight
Installation of Counterweight
Main Frame
Removal of Main Frame
Installation of Main Frame
Engine
Preparation before Removal of Engine
Removal of Covers and Related Parts Around the Engine
Removal of Wire Harnesses and Hoses Around the Engine
Removal of Engine Body
Installation of Engine Body
Installation of Wire Harnesses and Hoses Around the Engine
Installation of Related Parts of the Engine
Work after Installation of Engine and Installation of Covers
Radiator Assembly
Removal of Radiator
Installation of Radiator
Removal of Intercooler
Installation of Intercooler
Removal of Oil Cooler
Installation of Oil Cooler
Hydraulic Oil Tank
Removal of Hydraulic Oil Tank
Installation of Hydraulic Oil Tank
Fuel Tank
Removal of Fuel Tank
Installation of Fuel Tank
WJBQ40-EN-00(3)(20200624)
UPPERSTRUCTURE
Pump Device
Removal of Pump Device
Installation of Pump Device
Disassembly of Pump Transmission
Assembly of Pump Transmission
Disassembly of Main Pump
Assembly of Main Pump
Disassembly of Regulator for Main Pump
Assembly of Regulator for Main Pump
Disassembly of Fan Pump
Assembly of Fan Pump
Disassembly of Regulator for Fan Pump
Assembly of Regulator for Fan Pump
Structure of Pilot Pump
Control Valve
Removal of Control Valve
Installation of Control Valve
Disassembly of Housing
Assembly of Housing
Disassembly of Spool (A-Side Control Valve)
Assembly of Spool (A-Side Control Valve)
Disassembly of Boom 1 Anti-Drift Valve (d) (A-Side Control Valve)
Assembly of Boom 1 Anti-Drift Valve (d) (A-Side Control Valve)
Disassembly of Overload Relief Valves (e, f, z) (A-Side Control Valve)
Assembly of Overload Relief Valves (e, f, z) (A-Side Control Valve)
Disassembly of Pump 1 Bypass Shut-Out Valve (g) (A-Side Control Valve)
Assembly of Pump 1 Bypass Shut-Out Valve (g) (A-Side Control Valve)
Disassembly of Arm Regenerative Cut Valve (h) (A-Side Control Valve)
Assembly of Arm Regeneration Cut Valve (h) (A-Side Control Valve)
Disassembly of Bucket Regeneration Cut Valve (n) (A-Side Control Valve)
Assembly of Bucket Regeneration Cut Valve (n) (A-Side Control Valve)
Disassembly of Check Valve (p) (A-Side Control Valve)
Assembly of Check Valve (p) (A-Side Control Valve)
Disassembly of Auxiliary Flow Combiner Valve (q) (A-Side Control Valve)
Assembly of Auxiliary Flow Combiner Valve (q) (A-Side Control Valve)
Disassembly of Arm 2 Flow Rate Control Valve (r) (A-Side Control Valve)
Assembly of Arm 2 Flow Rate Control Valve (r) (A-Side Control Valve)
Disassembly of Boom Flow Rate Control Valve (s) (A-Side Control Valve)
Assembly of Boom Flow Rate Control Valve (s) (A-Side Control Valve)
Disassembly of Check Valve (t) (A-Side Control Valve)
Assembly of Check Valve (t) (A-Side Control Valve)
Disassembly of Load Check Valve (Bucket Parallel Circuit) (u) (A-Side Control Valve)
Assembly of Load Check Valve (Bucket Parallel Circuit) (u) (A-Side Control Valve)
Disassembly of Flow Combiner Valve (v) (A-Side Control Valve)
Assembly of Flow Combiner Valve (v) (A-Side Control Valve)
Disassembly of Check Valve (Bucket Flow Combiner Circuit) (w) (A-Side Control Valve)
Assembly of Check Valve (Bucket Flow Combiner Circuit) (w) (A-Side Control Valve)
Disassembly of Boom Regenerative Valve (x) (A-Side Control Valve)
Assembly of Boom Regenerative Valve (x) (A-Side Control Valve)
Disassembly of Load Check Valve (Arm 2 Tandem Circuit) (y) (A-Side Control Valve)
Assembly of Load Check Valve (Arm 2 Tandem Circuit) (y) (A-Side Control Valve)
Disassembly of Make-Up Valve (Boom) (aa) (A-Side Control Valve)
Assembly of Make-Up Valve (Boom) (aa) (A-Side Control Valve)
Disassembly and Assembly of Plugs (A-Side Control Valve)
Disassembly of Spool (B-Side Control Valve)
Assembly of Spool (B-Side Control Valve)
Disassembly of Arm Rod Anti-Drift Valve (e) (B-Side Control Valve)
Assembly of Arm Rod Anti-Drift Valve (e) (B-Side Control Valve)
Disassembly of Boom Anti-Drift Valve (f) (B-Side Control Valve)
Assembly of Boom Anti-Drift Valve (f) (B-Side Control Valve)
Disassembly of Overload Relief Valves (d, y) (B-Side Control Valve)
Assembly of Overload Relief Valves (d, y) (B-Side Control Valve)
Disassembly of Auxiliary Overload Relief Valves (p, ac) (B-Side Control Valve)
Assembly of Auxiliary Overload Relief Valves (p, ac) (B-Side Control Valve)
Disassembly of Boom Overload Relief Valve (z) (B-Side Control Valve)
Assembly of Boom Overload Relief Valve (z) (B-Side Control Valve)
Disassembly of Main Relief Valve (m) (B-Side Control Valve)
Assembly of Main Relief Valve (m) (B-Side Control Valve)
Disassembly of Check Valve (Main Relief Circuit) (n) (B-Side Control Valve)
Assembly of Check Valve (Main Relief Circuit) (n) (B-Side Control Valve)
Disassembly of Pump 2 Bypass Shut-Out Valve (q) (B-Side Control Valve)
Assembly of Pump 2 Bypass Shut-Out Valve (q) (B-Side Control Valve)
Disassembly of Load Check Valves (r, s) (B-Side Control Valve)
Assembly of Load Check Valves (r, s) (B-Side Control Valve)
Disassembly of Load Check Valves (t, u) (B-Side Control Valve)
Assembly of Load Check Valves (t, u) (B-Side Control Valve)
Disassembly of Load Check Valve (Boom 2 Parallel Circuit) (v) (B-Side Control Valve)
Assembly of Load Check Valve (Boom 2 Parallel Circuit) (v) (B-Side Control Valve)
Disassembly of Arm 1 Flow Rate Control Valve (w) (B-Side Control Valve)
Assembly of Arm 1 Flow Rate Control Valve (w) (B-Side Control Valve)
Disassembly of Swing Flow Rate Control Valve (x) (B-Side Control Valve)
Assembly of Swing Flow Rate Control Valve (x) (B-Side Control Valve)
Disassembly of Load Check Valve (aa), Check Valve (ab) (B-Side Control Valve)
Assembly of Load Check Valve (aa), Check Valve (ab) (B-Side Control Valve)
Disassembly and Assembly of Plugs (B-Side Control Valve)
Swing Device
Removal of Swing Device
Installation of Swing Device
Disassembly of Swing Reduction Gear
Assembly of Swing Reduction Gear
Disassembly of Swing Motor
Assembly of Swing Motor
Pilot Valve
Removal of Pilot Valve (Left)
Installation of Pilot Valve (Left)
Removal of Pilot Valve (Right)
Installation of Pilot Valve (Right)
Disassembly of Pilot Valves (Left and Right)
Assembly of Pilot Valves (Left and Right)
Removal of Travel Pilot Valve
Installation of Travel Pilot Valve
Disassembly of Travel Pilot Valve
Assembly of Travel Pilot Valve
Solenoid Valve
Removal of Pilot Shut-Off Solenoid Valve
Installation of Pilot Shut-Off Solenoid Valve
Disassembly of Pilot Shut-Off Solenoid Valve
Assembly of Pilot Shut-Off Solenoid Valve
Removal of 4-Spool Solenoid Valve Unit (Control Valve Side)
Installation of 4-Spool Solenoid Valve Unit (Control Valve Side)
Removal of 4-Spool Solenoid Valve Unit (Hydraulic Oil Tank Side)
Installation of 4-Spool Solenoid Valve Unit (Hydraulic Oil Tank Side)
Structure of 4-Spool Solenoid Valve Unit
Signal Control Valve
Removal of Signal Control Valve
Installation of Signal Control Valve
Structure of Signal Control Valve
Aftertreatment Device
Removal of Aftertreatment Device
Installation of Aftertreatment Device
WJBQ40-EN-00(4)(20200624)
UPPERSTRUCTURE
DEF Tank
Removal of DEF Tank
Installation of DEF Tank
Removal of DEF Tank Suction Filter
Installation of DEF Tank Suction Filter
Removal of DEF Tank Water Supply Inlet Filter
Installation of DEF Tank Water Supply Inlet Filter
Assembly of DEF Tank Water Supply Inlet Filter
WJBQ40-EN-00(5)(20200624)
UPPERSTRUCTURE
Coolant Control Valve
Removal of Coolant Control Valve
Installation of Coolant Control Valve
DEF Supply Module
Removal of DEF Supply Module
Installation of DEF Supply Module
Fan Valve
Removal of Oil Cooler Fan Valve
Installation of Oil Cooler Fan Valve
Structure of Oil Cooler Fan Valve
Removal of Radiator Fan Valve
Installation of Radiator Fan Valve
Structure of Radiator Fan Valve
Fan Motor
Removal of Oil Cooler Fan Motor
Installation of Oil Cooler Fan Motor
Removal of Radiator Fan Motor
Installation of Radiator Fan Motor
Structure of Fan Motor
Shockless Valve
Removal of Shockless Valve
Installation of Shockless Valve
Structure of Shockless Valve
UNDERCARRIAGE
Swing Bearing
Removal of Swing Bearing
Installation of Swing Bearing
Disassembly of Swing Bearing
Assembly of Swing Bearing
Travel Device
Removal of Travel Device
Installation of Travel Device
Disassembly of Travel Device
Assembly of Travel Device
Disassembly of Travel Motor
Assembly of Travel Motor
Disassembly of Brake Valve
Assembly of Brake Valve
Center Joint
Removal of Center Joint
Installation of Center Joint
Disassembly of Center Joint
Assembly of Center Joint
Replacement of Body and Spindle
Track Adjuster
Removal of Track Adjuster
Installation of Track Adjuster
Disassembly of Track Adjuster
Assembly of Track Adjuster
Front Idler
Removal of Front Idler
Installation of Front Idler
Disassembly of Front Idler
Assembly of Front Idler
Upper and Lower Rollers
Removal of Upper Roller
Installation of Upper Roller
Removal of Lower Roller
Installation of Lower Roller
Disassembly of Lower Roller
Assembly of Lower Roller
Track
Removal of Track
Installation of Track
Assembly of Special Tool (ST1532) for Removal / Installation of Master Pin
FRONT ATTACHMENT
Front Attachment
Removal of Bucket
Installation of Bucket
Removal of Arm
Installation of Arm
Removal of Boom
Installation of Boom
Removal of Bushing
Installation of Bushing
Cylinder
Removal of Boom Cylinder
Installation of Boom Cylinder
Disassembly of Boom Cylinder
Assembly of Boom Cylinder
Removal of Arm Cylinder
Installation of Arm Cylinder
Disassembly of Arm Cylinder
Assembly of Arm Cylinder
Removal of Bucket Cylinder
Installation of Bucket Cylinder
Disassembly of Bucket Cylinder
Assembly of Bucket Cylinder
Disassembly of BE Bucket Cylinder
Assembly of BE Bucket Cylinder
Hose Rupture Valve
Removal of Hose Rupture Valve for Boom Cylinder
Installation of Hose Rupture Valve for Boom Cylinder
Structure of Hose Rupture Valve for Boom Cylinder
Removal of Hose Rupture Valve for Arm Cylinder
Installation of Hose Rupture Valve for Arm Cylinder
Structure of Hose Rupture Valve for Arm Cylinder (Bottom Side)
Structure of Hose Rupture Valve for Arm Cylinder (Rod Side)
SERVICE MANUAL REVISION REQUEST FORM
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