Hitachi Ex3600-6 Hydraulic Excavator Technical Operator’s Manual (EM18M-1-1T)
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Hitachi Ex3600-6 Hydraulic Excavator Technical Operator’s Manual (EM18M-1-1T)
- Manual Language:English
- Pages: 306
- Size: 11.5 MB
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Hitachi Ex3600-6 Hydraulic Excavator Technical Operator’s Manual (EM18M-1-1T)
- Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury and/or machine damage.
- This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.
- This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.
- Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.
- Warranty is provided as a part of Hitachi‘s support program for customers who operate and maintain their equipment as described in this manual.
- The warranty is explained on the warranty certificate which you should have received from your dealer. This warranty provides you the assurance that Hitachi will back its products when defects occur within the warranty period. in some circumstances. Hitachi also provides field improvements. often without charge to the customer, even if the product is out of warranty. Should the equipment be abused or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or othen~ise overpowering machines will result in such action. Moreover. when replacement parts are required. be sure to use genuine Hitachi parts. Failure to do so may result in voiding the warranty and/or denial of field improvements. Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect/service the machine.
- The Yellow Pages in this operator’s manual contain IMPORTANT SAFETY INFORMATION. Read these pages thoroughly and familiarize yourself with the safety standards and recommendations set forth in these yellow pages of the manual. Follow all safety instructions prior to and while operating the excavator.
- Prior to operating this machine, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of your country. Please do not operate this machine until such comliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized concerning compliance.
Table of Contents:
Hitachi Ex3600-6 Hydraulic Excavator Technical Operator’s Manual (EM18M-1-1T)
SAFETY
Recognize Safety Information…………………………S-1
Understand Signal Words………………………………S-1
Follow Safety Instructions………………………………S-2
Prepare for Emergencies……………………………….S-2
Wear Protective Clothing……………………………….S-3
Protect Against Noise ……………………………………S-3
Inspect Machine……………………………………………S-3
General Precautions for Cab ………………………….S-4
Use Handholds and Steps……………………………..S-5
Adjust the Operator’s Seat …………………………….S-5
Fasten Your Seat Belt……………………………………S-6
Move and Operate Machine Safely …………………S-6
Handle Starting Aids Safely ……………………………S-6
Operate Only from Operator’s Seat…………………S-7
Jump Starting ………………………………………………S-7
Keep Riders Off Machine ………………………………S-7
Investigate Job Site Beforehand……………………..S-8
Protect Against Falling Stones and Debris ……….S-8
Provide Signals for Jobs Involving Multiple
Numbers of Machines ……………………………..S-9
Confirm Direction of Machine to be Driven……….S-9
Drive Machine Safely…………………………………..S-10
Avoid Injury from Rollaway Accidents…………….S-11
Avoid Injury from Back-Over
and Swing Accidents ……………………………..S-12
Keep Person Clear from Working Area………….S-13
Never Position Bucket Over Anyone ……………..S-13
Avoid Undercutting ……………………………………..S-13
Avoid Tipping……………………………………………..S-14
Never Undercut a High Bank………………………..S-14
Dig with Caution………………………………………….S-15
Operate with Caution …………………………………..S-15
Avoid Power Lines ………………………………………S-15
Object Handling ………………………………………….S-16
Protect Against Flying Debris ……………………….S-16
Park Machine Safely……………………………………S-17
Handle Fluids Safely − Avoid Fires………………..S-17
Practice Safe Maintenance…………………………..S-18
Warn Others of Service Work ………………………S-19
Support Machine Properly ……………………………S-19
Stay Clear of Moving Parts …………………………..S-19
Prevent Parts from Flying …………………………..S-20
Store Attachments Safely …………………………….S-20
Prevent Burns …………………………………………….S-21
Replace Rubber Hoses Periodically ………………S-21
Avoid High-Pressure Fluids ………………………….S-22
Prevent Fires ……………………………………………..S-23
Evacuating in Case of Fire……………………………S-24
Beware of Exhaust Fumes …………………………..S-24
Precautions for Welding and Grinding……………S-25
Avoid Heating Near Pressurized Fluid Lines …..S-25
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………….S-25
Remove Paint Before Welding or Heating …….. S-26
Beware of Asbestos Dust……………………………. S-26
Prevent Battery Explosions …………………………. S-27
Service Air Conditioning System Safely………… S-27
Handle Chemical Products Safely………………… S-28
Dispose of Waste Properly …………………………. S-28
SAFETY SIGNS ……………………………. S-29
COMPONENTS NAME ……………………. 1-1
HANDLING STAIRWAY/EMERGENCY ROPE
Using Stairway ……………………………………………. 1-2
Operating Stairway………………………………………. 1-2
Emergency Escape……………………………………… 1-5
Emergency Exit …………………………………………… 1-6
Evacuating in Case of Fire ……………………………. 1-6
OPERATOR’S STATION
Cab Features ……………………………………………….1-8
Monitor Display……………………………………………..1-9
Starting Check Screen …………………………………..1-9
Meter Check Screen ……………………………………1-10
Tachometer…………………………………………..1-11
Coolant Temperature Gauge …………………..1-11
Hydraulic Oil Temperature Gauge ……………1-11
Fuel Gauge …………………………………………..1-11
Engine Oil Pressure Gauge …………………….1-12
Engine Oil Temperature Gauge……………….1-12
Hour Meter ……………………………………………1-12
Warning Indicators…………………………………1-12
Alternator Indicator…………………………………1-12
Pump Transmission Oil Level Indicator …….1-13
Engine Stop Indicator……………………………..1-13
Engine Oil Pressure Indicator ………………….1-13
Coolant Overheat Indicator ……………………..1-13
Coolant Level Indicator …………………………..1-14
Engine Over Run Indicator………………………1-14
Fuel Temperature Indicator …………………….1-14
Hydraulic Oil Level Indicator ……………………1-14
Stop Valve Indicator ……………………………….1-15
Auto-Lubrication Indicator ……………………….1-15
Fast-Filling Indicator……………………………….1-16
Emergency Engine Stop Indicator ……………1-16
Tension Indicator …………………………………..1-16
Electric Lever Indicator …………………………..1-16
Caution Indicators ………………………………….1-17
Exhaust Temperature Indicator ……………….1-17
Engine Warning Indicator ……………………….1-17
Hydraulic Oil Overheat Indicator ………………1-17
Pump Contamination Indicator…………………1-17
Stairway Position Indicator………………………1-18
Air Cleaner Restriction Indicator ………………1-18
Electrical Equipment Box Indicator …………..1-18
Status Indicators ……………………………………1-18
Auto-Idle Indicator………………………………….1-18
Travel Mode Indicator……………………………. 1-19
Prelub Indicator …………………………………….1-19
Left Console………………………………………………. 1-20
Warning Lamp………………………………………1-20
Caution Lamp ……………………………………….1-20
Key Pad ……………………………………………….1-20
Monitor Contrast Switch ………………………… 1-20
Wiper Switch ………………………………………..1-21
Washer Switch ……………………………………..1-21
Wiper Delay Selector Switch ………………….. 1-21
Air Conditioners …………………………………………. 1-22
Designations And Functions Of Controls……….. 1-23
Cooling ………………………………………………..1-25
Heating ………………………………………………..1-25
Dehumidifying And Heating ……………………. 1-25
Defrosting …………………………………………….1-26
Blower Operation Without Cooling
or Heating……………………………………….1-26
Ventilation The Cab………………………………. 1-26
AM/FM Radio Operation ……………………………… 1-27
Digital Clock Setting Procedure……………………. 1-28
Right Console ……………………………………………. 1-29
Key Switch……………………………………………1-29
Emergency Engine Stop Switch ……………… 1-30
Engine Start Switch ………………………………. 1-30
Engine Stop Switch ………………………………. 1-30
Engine Speed Control Dial …………………….. 1-31
Work Light Switch…………………………………. 1-32
Dome Light Switch………………………………… 1-33
Maintenance Light Switch………………………. 1-34
Entrance Light Switch……………………………. 1-35
Travel Mode Switch………………………………. 1-36
Auto-Idle Switch…………………………………….1-36
Buzzer Stop Switch……………………………….. 1-37
Fast-Filling System……………………………….. 1-38
Rear Console…………………………………………….. 1-39
Horn Switch ………………………………………………. 1-40
Adjusting The Seat …………………………………….. 1-41
Seat Belt …………………………………………………… 1-44
Cab Door Release Button……………………………. 1-45
Opening Cab Left Window…………………………… 1-45
BREAK-IN
Observe Machine Closely……………………………… 2-1
Every 10 Hours or Each Shift ………………………… 2-1
After the First 50 Hours ………………………………… 2-2
OPERATING THE ENGINE
Inspect Machine Daily Before Starting…………….. 3-1
Before Turning Power ON …………………………….. 3-2
Turning Power ON……………………………………….. 3-3
Starting the Engine ………………………………………. 3-8
Starting in Cold Weather ………………………………. 3-9
Check Instruments after Starting………………….. 3-10
Using Booster Batteries ………………………………. 3-11
Stopping the Engine …………………………………… 3-13
Stopping the Engine in Emergency
(In The Cab)………………………………………….3-14
Stopping the Engine in Emergency
(Except In The Cab)……………………………….3-15
DRIVING THE MACHINE
Drive the Machine Carefully ……………………………4-1
Steering the Machine Using Pedals …………………4-2
Steering the Machine Using Levers …………………4-3
Travel Mode Switch……………………………………….4-4
Travel Alarm…………………………………………………4-5
Traveling ……………………………………………………..4-6
Operating on Soft Ground………………………………4-7
Raise One Track Using Boom and Arm……………4-7
Towing Machine a Short Distance …………………..4-8
Operating Ground Condition …………………………..4-9
Precautions for Traveling on Slopes ………………4-10
Parking the Machine on Slopes …………………….4-11
Parking the Machine ……………………………………4-11
OPERATING THE MACHINE
Control Lever (ISO Pattern Backhoe) …………….5-1
Control Lever (HITACHI Pattern Backhoe) ……..5-2
Control Lever (ISO Pattern Loading Shovel) ……5-3
Control Lever (HITACHI Pattern
Loading Shovel) …………………………………….5-4
Bucket Open-Close Pedals (Loading Shovel)……5-5
Pilot Control Shut-Off Lever ……………………………5-6
Engine Speed Control ……………………………………5-7
Auto-Idle………………………………………………………5-8
Warming-Up Operation………………………………….5-9
Warming-Up the Cylinders and Motors…………..5-10
Precautions for Operations …………………………..5-11
Operate the Machine Safely………………………….5-12
Operating Backhoe ……………………………………..5-13
Grading Operation……………………………………….5-13
Avoid Abusive Operation………………………………5-14
Operating Tips…………………………………………….5-15
Avoid Swinging Bucket to Move Objects…………5-15
Loading Shovel Operation…………………………….5-16
Prohibited Operation ……………………………………5-16
Object Handling…………………………………………..5-18
Overnight Storage Instructions………………………5-19
MAINTENANCE
Correct Maintenance and Inspection Procedures….7-1
Check the Hour Meter Regularly……………………..7-2
Use Correct Fuels and Lubricants …………………..7-2
Prepare Machine for Maintenance…………………..7-3
Open Access Doors for Service………………………7-5
Inspection/Maintenance Lights………………………..7-6
Use a Chain to Prevent Falling Accidents…………7-7
Electric Pump (Optional) ………………………………..7-8
Construction Outline…………………………………….7-10
Hydraulic System ………………………………………..7-11
Periodic Replacement of Parts ……………………..7-14
Periodic Replacement of Rubber Hoses ……….. 7-15
Maintenance Interval Guide…………………………. 7-20
A. Greasing …………………………………………….7-24
Loading Shovel Front Joint Pins……………… 7-25
Backhoe Front Joint Pins ………………………. 7-28
Swing Bearing ………………………………………7-31
Swing Internal Gear………………………………. 7-32
Center Joint ………………………………………….7-33
Operating the Lubricator………………………… 7-34
B. Engine …………………………………………………7-36
Engine Oil Level in Engine Oil Pan………….. 7-37
Check LED Monitor Signal
(on Reserve Tank) ………………………….. 7-38
Change Engine Oil in Engine Oil Pan………. 7-39
Replace Engine Oil Filters ……………………… 7-39
C. Transmission ………………………………………7-43
Pump Transmission Gear ……………………… 7-44
Pump Transmission Oil Level…………………. 7-44
Change Oil…………………………………………… 7-45
Replace Filter ……………………………………….7-46
Clean Breather …………………………………….. 7-46
Swing Reduction Gear…………………………… 7-47
Check Oil Level ……………………………………. 7-47
Change Gear Oil…………………………………… 7-48
Clean Breather …………………………………….. 7-48
Travel Reduction Gear ………………………….. 7-49
Check Oil Level ……………………………………. 7-49
Change Gear Oil…………………………………… 7-50
D. Hydraulic System…………………………………..7-51
Inspection and Maintenance
of Hydraulic Equipment ……………………. 7-52
Check Hydraulic Oil Level ……………………… 7-54
Drain Hydraulic Oil Tank Sump ………………. 7-55
Change Hydraulic Oil…………………………….. 7-56
Replace Full-Flow Filter and Drain Filter ….. 7-59
Replace Bypass Filter……………………………. 7-61
Replace Pilot Oil Filter …………………………… 7-63
Suction Filter ……………………………………….7-65
Replace Suction Filter …………………………… 7-66
Replace High-Pressure Strainer……………… 7-67
Clean Oil Cooler Core …………………………… 7-68
Check Hoses and Lines ………………………… 7-69
Service Recommendations for
Hydraulic Fittings ……………………………..7-72
E. Fuel System………………………………………….7-74
Drain Fuel Tank Sump ………………………….. 7-76
Drain Fuel Filter Sediment……………………… 7-76
Replace Fuel Element …………………………… 7-77
Replace Fuel Filter ……………………………….. 7-78
Check Fuel Hoses ………………………………… 7-79
F. Air Cleaner…………………………………………… 7-81
Clean Air Cleaner Outer Element……………. 7-81
Replace Air Cleaner Outer
and Inner Elements …………………………. 7-81
G. Cooling System …………………………………….7-83
Check Coolant Level …………………………….. 7-84
Check DCA4 Concentration in Coolant……..7-85
Replace Coolant Filter ……………………………7-93
Change Coolant …………………………………….7-94
Clean Radiator Interior……………………………7-94
Clean Radiator Core ………………………………7-96
H. Air Conditioner ………………………………………7-97
Recirculation Air Filter…………………………….7-97
Ventilation Air Filter ………………………………..7-98
Check Refrigerant Quantity……………………..7-99
Check Compressor Belt Tension ……………7-100
Clean Condenser Core …………………………7-101
Check Tightening Torque ……………………..7-102
Seasonal Maintenance …………………………7-103
I. Electrical System ………………………………..7-104
Batteries……………………………………………..7-104
Replace Batteries…………………………………7-108
Replacing Fuses ………………………………….7-109
Power Source Terminal ………………………..7-112
High Current Fuse………………………………..7-113
Check Electrical Cables and
Wire Harnesses for Short Circuits …….7-115
Check Emergency Engine Stop Switch …..7-117
J. Miscellaneous ……………………………………7-118
Check Bucket Teeth …………………………….7-119
Inspect Emergency Evacuation
Equipment and Hanger……………………7-121
Auto-Lubrication System……………………….7-122
Check and Replace Seat Belt ………………..7-126
Check Windshield Washer Fluid Lever……7-126
Clean Air Horn Compressor Filter…………..7-127
Check and Adjust Track Sag …………………7-128
Check Accumulator and Track
Adjuster Cylinder Circuit ………………….7-130
Check Side Frame Area ……………………….7-130
Check Tightening Torque of Bolts
and Nuts………………………………………..7-131
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special
Environmental Conditions …………………………9-1
STORAGE
Storing the Machine …………………………………….10-1
Removing the Machine from Storage …………….10-2
Transporting the Machine …………………………….10-2
TROUBLESHOOTING
Cummins Fault Code Lamps and
Diagnostic Switches……………………………….11-1
Engine ……………………………………………………….11-2
Electrical System…………………………………………11-6
Mode Selection …………………………………………..11-9
Hydraulic System ………………………………………..11-9
Auto-Idle…………………………………………………..11-12
SPECIFICATIONS
Specifications …………………………………………… 12-1
Working Range (Loading Shovel)…………………. 12-2
Working Range (Backhoe) ………………………….. 12-3
INDEX ……………………………………………………. 14-1
Please Note:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
Carson Kannon –
Easy to use, manual appears to be complete.