Cẩu HITACHI KH180

Cẩu HITACHI KH180 Catalogue cẩu hitachi KH180

APPLICABLE MACHINE SERIAL No 0564 EM203—2—2E

load to the boom

at 30° to 80° regardless

of length of boom

hydraulic components and pneumatic components by yourself

and hydraulic system before attempting to operate the machine

and hoist brake and release clutch if engine stalls during operation

Or supporting plates under tracks, if necessary

a ll Stop all operations when the L

velocity of wind exceeds 10

m/sec

late causes if readings are not correct

Remove the rear counterweight whenever spreading with front-

end attachment off machine

Avoid sudden applications of

all controls, particularly

at start and end of each

when operating with heavy or high load, or with bulky material or long objects

16

Do not raise or lower boom

boom off the ground when pendant rope is attached

to lower boom

in crane operation

switch while engine is in

rotation

seize live end with wire or

all safety devices before to using machine

22 DO not use machine for other

don't let anyone to get on clamshell bucket for

transport

when there is a danger of a bank caving in on it, or when rains are likely to wash out

between groundman and ope-

rator under such conditions

and level ground as possible when performing daily inspec-

block each crawlers if serv-

25 Do not operate machine until

a warning signal is given and

all workers are clear

26 When self-disassembling the boom, connect the bridle sheave

to the lower boom bracket

Then, remove the lower connect—

sure that the end of the lower

May cause a fire

if the main and/or auxiliary

hoist brakes are released

PROTECTIVE AND SAFETY GUIDEPOINTS

ON THE USE OF "VIBRO-HAMMER"

Three basic rules

l Limit the boom angle (and hence the working radius) so that lift-

ing formula:

Rated capacity = gross VIBRO-HAMMER weight*

2 NOTE: *Inclusive of the weights of hook and pile

2 Make sure that the pile extracting force is always perpendicular

Use a gantry or similar supporting frame

3 Suspend the spring-type damper of the hammer with a multi-part

cable line pending from the top of the supporting frame

The VIBRO-HAMMER drives by the force of vtbratton

All necessary precauttons stem from this knowledge

When you start extracting the pile, there's no telling just how

rule for any craneman is: "Never try to lift a load that you can-

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 "A" structure, which props up the boom as shown (see the

ment, the force for hoisting the pile from ground through the

spring-type damper and hammer 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

the springs would be stretched as far as they can: under this

condition, the vibration would directly act on the boom; and this

force, coupled with that of pile extraction (to constitute a

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 hammer is a

bad practice: a hook so connected could fail due to the vibration

Example of "A" support frame for VIBRO~HAMMER operation

Have boom hoist rope slackened during pile

is 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

but the gain is imaginary: clutches might overheat and seize or,

to use an "A" frame similar to the one illustrated above.

FOREWORD

This Instruction Manual contains information on the operation, lubri-

cation and maintenance of the Hitachi KH180-2 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 KH180-2 Crawler Crane will greatly de-

ues 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, vefer

to the Engine Operator's Manual published separatedly for the purpose

This operation manual applies to the machine with Serial No 203-0564

Hitachi Construction Machinery Co., Ltd.

CONTENTS

Page SPECIFICATION AND DIMENSIONS 2.2 ccc csc we cence ncn n ne caee +

CONSTRUCTION o ccc ec ec cc ee me eee ere eee eee eee eee nee ence sees 10

SAFETY DEVICH 2 ccc ccc ccc cee ee rece tere een eee eee we wee eee 18

OPERATION

INSPECTION, MAINTENANCE AND ADJUSTMENT .ccccccaes 60

5.3.2 Hydraulic o11 tank 2 ee ee ce ee wee ee eee 78 5.3.3 Hydraulic oil filter oo cece cece cece e cece ee eeees 79

INSPECTION AND MAINTENANCE cc cece cece eee cr eee ee ee ween eeee 89

6.9 Instructions for Disassembly and Repair .208 102 6.10 Cares in Long Outage 2 eee c cece cece cen eee e ccc eccnvee 104 6.11 Maintenance Services Under Unusual Conditions 104

ASSEMBLY AND DISASSEMBLY OF FRONT END ATTACHIMENT 106

7.1 Disassembling and Assembling of Crane Front 106 7.1.1 Crane boom 2 cece cece cece e cece eee c ec eceeeaece 106 7.1.2 Removal and installation of jib boom 113 7.1.3 Installing and removing the auxiliary jib 116 7.1.4 Lowering high A-frame 1 cece ee ee ee ee eee 118 7.2 Installation and Removal of Clamshell Attachment ¬— ee 120 7.3 PYECAULTLONS Loe eee ee ee eee eee ce eee ce cee eee tees ee eece 120

WIRE ROPES 2 cw cece cc ce ewer ee eee ee tere reece tere ere eases 121

8.1 Handling of Wire ROpeS 2 ccc eee cee eee ee cee ene tenes 121

8.4 Standard Wire ROPES 2 ee cee eee en ccc new we cece eee VY 1 11 126

TRANSPORTATION 2.02 c ccc wcrc eee cree ence e cence eee eee cect eacace 130

9.2 Transporting on Trailer 2 eee 9.2.1 Precautions Lee e esc c ccc cc wc cee cc eee ce este ere ce eeee ee eee eee eee nee

1 SPECIFICATION AND DIMENSIONS

the rear)

Engine rated output

Crane gross weight

ISUZU E120TPZ (DIESEL)

46700kg (With base boom and 50Ton hook)

(With base boom and 50Ton hook)

standing on firm level surface

SYS

Table’ 1-3 No of Parts of Line VS Maximum Rated Load

2 CONSTRUCTION

The Hitachi KH180-2 Crawler Crane is a crawler-mounted hydraulic

volving frame and cab (or upper workds); track frame and crawler as-

sembly (or lower works); and various front end attachments to use as

the operator know how to perform every operation of which the crane

Observe the instructions on how to coordinate the basic motions to

perform the specific task for which the crane is intended

Many troubles are caused by the abuse or misuse of machines, due to

machine, it is essential that the manual be read through, in order

that you may result in safer, better result

Fig 2-1 shows an exaggerated view of the crane so that position of

the major units relative to each other can be seen

2.1 Power Transmitting System

All operations are full hydraulic as illustrated schematically in

all the operations of the crane and front end attachment are carried

out

The engine provides motive power for driving the hydraulic pumps

which in turn supply pressure oil through the control valves to the

various hydraulic motors, depending upon which way the control levers

are operated

The hydraulic motors then operate the winch drums and drive tumblers

through the speed reduction gearing for each crawler

The pilot valves at the lever tower in the cab actuate the control

valves so as to perform the basic motion of this machine, such as

raising and lowering of the load, swinging the upper works, and ele-

vating and lowering of the crane boom

Pressure reltef valves tn the hydraulte ctreutts prevent abnormal

pressure from betng attatned wtthin the system

Under no etreumstances should the adjustments of these valves be

tervals, tf the machtne ts to funetton properly

~10~

2.2 Electrical System

A schematic diagram of the electric

system is shown in Fig 2-4

As will be seen from the diagram, the

crawler crane electrical system uses

a battery powered, negative grounded

24-volt system in which two 12-v batt-

eries are connected in series

When tt becomes necessary to replace

blown-out fuses or broken wtre cables, use the ones having the

spectfted capactty or of proper rating as shown in Fig 2-4

Battery

Swing unit

Fuel tank

PV: Variable displacement

i hydraulic pump

| MF: Fixed displacement hydraulic

Fig

-13-

Intake air heater switch

Feed pump magnetic

N8 c 8&6 mĩ \ T1 — pe ] Ó.IBE lamp | | 4 |

7

AVI.25 L/wW = c5Âo (clutch oN) (clutch ON)

Rt OFF ace B |RilAedR2| c [BR Thermometer F3 4

4) In the case of no boom overhoist switch (1)

Short Fig 2-4 Schematic Diagram of Electrical System

2.3

(1)

Air System Fig 2-5 shows schematic diagram of air system

The compressed air acts as follows

To aid the suction of the hydraulic pump, give pressure to the hydraulic tank

safety valve 8.2V9.0bar

+

Auto drain valve

Low pressure safety valve

Flange plug Air vent plug

Check valve Reducing valve

0 8bar (0.8kg/cm2)

¬

1.8bar (1.8kg/cm”)

r

Check valve

Air san _—_

of the major devices and the flow of the compressed air

The highly pressurized air from the compressor is sent into the air tank through the air filter which removes the water

and oil in the air

through the reducing valve

drain plug

valve to drain away automattcally

Then, it gives pressure to the oil tank

The atr filter ts equipped wtth a

The air tank is equtpped with an automatic drain

Also, the air and oil tanks

have safety valves which protect the circuit

The high and low pressure safety valves, reductng valve and governor are adjusted prtor to leaving the factory

Never dtsassemble them and/or touch thetr adjusting screws, because they cannot be readjusted at your site

abnormaltty ts found on them, shop for repatr

-17-

In the event that any contact your nearest Httacht servce

3 SAFETY DEVICE

3.1 Hook Overhoist Prevention Device

In the following figure, the microswitch is always closed by the

opened, that in turn activates the relay (4) in the side stand to

The solenoid valve (@) interrupts the pressure from the pilot valve

As a results, the spool in the control valve is returned to the neu-

the hook can be lowered)

The hook overhoist prevention device is released together with the

warning bell by pushing backward the release switch mounted on the

The release switch is returned automatically by spring when taking

your hand off it

(6) Auto-stop solenoid valve

Hook Overhoist Warning and Prevention Devices

Note:

(a) The uining for this device ts very tmportant to keep safety

So that, handle it with care, and be sure to contact nearest service shop when the wire ts broken or modtfted

(b) The wetght of the hook overhotst warning and _preventton devices

should be postttoned with the distance more than the distance shown in the rtght tllustratton

3.2 Boom Overhoist Prevention Device

The microswitch @) mounted on the boom foot is kept [ON] in normal

condition

The microswitch is opened by the bolt mounted on the boom foot when

lay (2) in the side stand is activated, and that in turn activates

interrupts the pilot pressure

As a result, the spool 6) in

neutral position to stop boom

the boom can be lowered)

The boom overhoist prevention

warning buzzer by pushing the

the control valve is returned to the

device is released together with the

release switch backward mounted on the

when taking your hand off it

Note:

(1) Adjust the bolt so that the _mtcroswitch may be "ON" at the boom

angle 80 degrees

(2) When the electrte wire between the microswtteh (1) and relay

(2) ts broken or off, the device is activated and the boom can-

not be ratsed

~19—

Boom Overhoist Warning and prevention (auto-stop) Devices 3.3 Funciton of Automatic Stop and Warning Devices

Continuous | Continuous | Hoisting | Boom

(1) The function of warnings and automatic stops of the hook and boom

overhoist prevention devices is as shown in above table Prior to

the operation, make sure that each function is normal under the

condition of no load attached on the hook

(2) Auto-stop release switches are provided on the side stand

Hook overhoist auto-stop release switch The overhoist auto-stop is released when the switch

is pushed backward

Boom lowering auto-stop release switch The boom lowering auto~stop is re- leased when the switch is pushed backward

(This switch is unnecessary whenthe load meter is pro- vided)

Front

Boom hoisting auto-stop release switch The boom hoisting auto~stop is re- leased when the switch is pushed backward

Side stand Note: Auto-stop releasing

All release switches are of auto-~

return type So that, usually,

auto-stop function is always effective

[Caution for applying the auto-stop release switch]

(The switch is always put in "Auto-stop” position unless any other force is applied because all switches are of spring return type)

(b) Do not put anything on the side stand, lest it shoul put the

switch in "Release" position

-21~—

3.4 Hoist Brake

brake is applied by only stepping force through link and lever system

in case of light load condition, however, in case of heavy load con-

dition, the brake is applied by combined force of stepping and spring

Pump Tank

When controlling the hoist lever, for safety, be sure to step the

hoist brake pedal when the hoist control lever is returned to the

neutral position

Otherwise, the load will descend gradually under gravity due to leak-

age of the oil in the hydraulic oil motor

When the load is required to suspend in air for a long time, be sure

to step the brake pedal deeply and lock it