Ex1200 7b Ko 590 01 Assembly Manual

KO-590-01
ASSEMBLY
PROCEDURE
MANUAL
Foreword
Assembly work is the final touch that gives the machine life. The quality of a machine's
assembly affects its operative performance and service life of the machine.
Because a machine's value is determined by its assembly, those who do this work are
required to have sufficient know-how about assembly.
This manual basically contains assembly know-how such as methods and useful hints for
assembling the EX1200-7B Hydraulic Excavator. Please read this manual carefully and try
to keep it for reference before you engage in assembly or while you work.
This manual is a practical compilation of the following three viewpoints: "the improvement
of work safety", "the improvement of efficiency" and "the enhancement of product quality."
1) Safety: Some hints and information for safe work are provided, such as the
weight of the parts, their lifting points when raised with wire ropes and
their handling procedures.
Work safety is attained with this manual.
2) Quality: Procedures and hints are described for correct machine assembly. They
include the part numbers, tightening torque values of bolts, etc. Correct
assembly is essential to provide the machine with a longer service life at
maximum performance.
3) Efficiency: Tool jigs, the facilities necessary to do the work and the preparation
needed for each work stage are introduced to assure speedy and
effective completion.
We hope this manual will be helpful to you in assembling the machine without a hitch.
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CONTENTS
Pages
1. Precautions······················································································································································ 1
1-1. Safety precautions for servicemen············································································································ 1
1-2. How to use a power wrench···················································································································· 14
1-3. Work precautions···································································································································· 17
2. Workers plan (Backhoe front)························································································································ 29
2-1. Transportation (Backhoe front)················································································································ 30
3. Parts check······················································································································································ 41
3-1. Check······················································································································································ 41
4. Preparations (Backhoe front)························································································································· 42
5. Machines, apparatus, tools, and materials necessary for assembly·························································· 45
6. Assembly of upperstructure··························································································································· 51
6-1. Preparations············································································································································ 51
6-2. Connection of upperstructure and side frames······················································································· 57
6-3. Connection of travel motor hoses············································································································ 67
6-4. Assembly of cab & handrail, step and ladder etc.··················································································· 69
6-5. Installation of counterweight, SCR muffler, camera and rear lamps······················································· 79
6-6. Greasing of swing bearing······················································································································ 95
6-7. Vacuuming (air purge work) & charging of refrigerant············································································· 99
6-8. Final check of superstructure················································································································ 119
6-9. Releasing the air from the main pumps································································································ 123
6-10. Trial operation of superstructure············································································································ 125
6-11. Disassembly procedures for shipment·································································································· 126
7. Mounting procedures for backhoe front····································································································· 131
7-1. Preparation············································································································································ 131
7-2. Mounting of backhoe boom··················································································································· 141
7-3. Mounting of arm···································································································································· 151
7-4. Mounting of bucket································································································································ 161
7-5. Adjustment of track link tension············································································································ 171
7-6. Final trial operation check····················································································································· 173
7-7. Disassembly procedures for shipment·································································································· 174
8. Checks after completing the assembly······································································································· 181
9. Checking machine performance·················································································································· 185
Assembly check sheet·································································································································· 195
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EX1200-7B Backhoe front
Bucket Bucket cylinder

Front attachment
Arm cylinder
Boom
Urea tank
Arm Upperstructure
Swing drive
Fuel tank
Boom cylinder
Oil cooler
Engine
Cab
Radiator
iii
Track link assembly
SCR Exhaust
Front idler
Track spring Counterweight
Upper roller
Lower roller
Pump
Undercarriage Final drive
EX1200-7B Assembly Process Chart
BACKHOE FRONT
iv
Weight: 116 000 kg (255 734 lb) Standard
Weight: 118 000 kg (260 143 lb) BE
1. Precautions
1-1 Safety precautions for servicemen
1 RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe operating

practices.
Fig. 1-1
2 UNDERSTAND SIGNAL WORDS

Machine safety signs incorporate signal words -
DANGER, WARNING and CAUTION - to designate the
degree or level of hazard.
DANGER indicates an imminently hazardous situation

which, if not avoided, will potentially result in death or
serious injury.
WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate
injury.
The NOTE describes cautionary remarks, reference,

etc. for assembly.
DANGER and WARNING safety signs are located near

Fig. 1-2
specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety items in
this manual.
To avoid confusing machine protection with personal

safety messages, IMPORTANT is used to indicate a
situation which, if not avoided, could result in damage
to the machine.
1
3 FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained, and

replaced when necessary.
If a safety sign or this manual is damaged or missing,
order a replacement from your Hitachi dealer in the
same way as you order other replacement parts (be
sure to state the machine model and serial number
when ordering.) Fig. 1-3
Learn how to operate the machine and its controls

correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair
its functions and/or safety, and affect machine life.
The safety messages in this chapter are intended to

illustrate basic safety procedures for hydraulic
excavators. However it is impossible for these safety
messages to cover every hazardous situation you may
encounter. If you have any questions, you should first
consult your supervisor before operating or performing
maintenance work on the machine.
4 DESIGNATE ONE LEADER AND TWO

SUBLEADERS
In order to work with the greatest safety and ease,
designate a foreman and two subleaders as working
partners. When assembling the superstructure, station
the subleaders at the front and rear of the machine.
They should carry out and follow the leader's signals
with utmost care to avoid breakage of components and
personal injury.
Fig. 1-4
5 CLEAN THE MACHINE REGULARLY

Remove any grease, oil or dirt build-up to avoid
possible injury or machine damage.
Do not spray water or steam inside the cab.
Fig. 1-5
2
6 WEAR PROTECTIVE CLOTHING
Avoid wearing loose clothing, jewelry, or other items
that can catch on control levers or other parts of the
machine.
Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

• Hard hat
• Safety shoes
• Safety glasses, goggles, or a face shield
• Heavy gloves
• Hearing protection
• Reflective clothing
• Wet weather gear Fig. 1-6
• Respirator or filter mask.
7 PREPARE FOR EMERGENCIES

Be prepared for the eventuality of a fire.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance

service, a hospital, and the fire department near your
Fig. 1-7
telephone.
8 PREPARE SUITABLE LIFTING TOOLS

Work with this machine involves lifting heavy and bulky
items with a crane. Pay attention to the following
points:
a) Prepare suitable lifting tools.
b) To prevent unnecessary mishaps due to broken
wire cables, do not use damaged chains or frayed
cables, slings, or ropes. Be sure to use a proper
protector and patch.
c) Before proceeding with the work, agree on specific
signals with the crane operator and the designated
leader/subleader team.
d) Always keep the area directly below any load clear
of people during slinging work.
e) Service personnel and mechanics must check the
Fig. 1-8
weights given in this manual, and apply the proper
lifting procedures when removing any components.
f) When using hydraulic excavators for lifting
operations, be sure to comply with all local
regulations.
3
9 ENGINE SAFETY
a) No one should be allowed inside the hydraulic
excavator while it is being operated or during
assembly.
b) Keep hands away from moving parts.
c) Sound the horn as an alert to those nearby before
starting up the engine.
d) Start the engine from the operator's seat and never
while standing on the ground.
e) To avoid injury or possible machine damage, never
start the engine by shorting across the starter
terminals.
Fig. 1-9
10 SUPPORT RAISED BUCKET

Never work under or near a raised bucket. Lower the
bucket to the ground or onto secure blocks.
Fig. 1-10
11 SAFETY AT HEIGHT
Take adequate measures to avoid falling from high
spots during work. Clean any mud or debris from the
steps, walkways, or work platforms before work, and
use a safety belt during work.
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails. Do not use any controls as
handholds.
Before getting off, be sure to align the cab parallel with
the tracks.
Never jump on or off the machine. Never mount or

dismount a moving machine.
Be careful of slippery conditions on platforms, steps, Fig. 1-11

and handrails when getting off the machine.
4
12 FUEL SAFETY AND FLAMMABLE
MATERIALS
a) Never smoke while refueling or handling flammable
materials.
b) Shut the engine off while refueling.
c) Exercise caution when refueling while the engine is
still hot.
d) Do not clean parts using opened cans of gasoline
or diesel fuel. Use good, commercial, non-
flammable solvents.
Fig. 1-12
13 PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away from
the top of the battery. Battery gas can explode.
Never check the battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery - it may explode. Warm

the battery to 16°C (60.8°F).
Disconnect the negative ground cable before working

on the electrical system or making major repairs.
Fig. 1-13-1
Fig. 1-13-2
5
14 AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure, can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Relieve the pressure by moving the control levers
several times.
Tighten all connections before pressurizing the
hydraulic system.
• Search for leaks with a piece of cardboard, taking

care to protect your hands and body from high-
pressure fluids. Wear a face shield or safety goggles
for eye protection.
• If an accident occurs, see a doctor familiar with this Fig. 1-14-1

type of injury immediately.
Any fluid injected into the skin must be surgically
removed within a few hours, or gangrene may result.
Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4
15 CHECK EQUIPMENT SAFETY

a) Use a piece of cardboard or paper to safely check
for leaks in all systems, including the following:
Hydraulic system
Fuel system
b) Use the correct testing gauge type when checking
the hydraulic pressure.
c) Check all protective parts on the machine (shields,
guards, pins, etc.). They should be in good
condition and securely fastened.
d) Inspect electrical wiring for worn or frayed
insulation, and install new wiring if damage has
occurred.
Fig. 1-15
6
16 PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Fig. 1-16
17 FASTEN YOUR SEAT BELT

Prior to operating the machine, thoroughly examine the
belt, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
in question before operating the machine.
Be sure to remain seated with seat belt securely

fastened at all times when the machine is in operation.
Fig. 1-17
18 BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes, or open doors
and windows to bring enough fresh air into the area.
Fig. 1-18
7
19 PRACTICE SAFE MAINTENANCE
Understand service procedures before performing any
work. Keep the work area clean and dry.
Never lubricate or service the machine while it is

moving.
Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine.
• Park the machine on a level surface.

• Lower the bucket to the ground. Fig. 1-19-1
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 3
minutes.
• Turn the ignition OFF to stop the engines.
• Relieve the pressure in the hydraulic system by
moving the control levers several times.
• Remove the key from the ignition.
• Attach a "Do Not Operate" tag to the travel speed
select/pilot control shut-off lever
• Set the travel speed select/pilot control shut-off lever
to the P position.
• Allow the engine to cool.
If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
Boom
If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support Arm
any machine elements that must be raised for service
work. Never work under a machine raised by the boom.
Inspect certain parts periodically, and repair or replace 90 to

as necessary. Refer to the relevant section of the 110°
Operation Manual.
Keep all parts in good condition and properly installed. Fig. 1-19-2
Fix any damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil or debris.
Disconnect the battery ground cable (-) before making

adjustments to the electrical system or performing
welding work on the machine.
8
20 WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, attach a

"DO NOT OPERATE" tag to the travel speed
select/pilot control shut-off lever.
This tag is available from your authorized dealer.
Fig. 1-20
21 REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.
Remove paint before welding or heating:
1 If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
2 If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
Fig. 1-21
disperse at least 15 minutes before welding or
heating.
22 PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or
debris - wear goggles or safety glasses.
In order to avoid personal injury, keep bystanders away

from the working area when striking any object.
Fig. 1-22
9
23 PREVENT AGAINST FLYING PARTS
Grease in the track adjuster is under high pressure.
Do not attempt to remove a GREASE FITTING or
VALVE ASSEMBLY.
Be sure to keep your body and face away from any
valve, as pieces may fly off.
The travel reduction gears are under pressure.
So as to avoid injury from flying parts, be sure to keep
your body and face away from the AIR RELEASE
PLUG.
GEAR OIL is hot. Wait for the GEAR OIL to cool, then Fig. 1-23
gradually loosen the AIR RELEASE PLUG to release
pressure.
24 PREVENT BURNS
Hot spraying fluids:
• After operation, the engine coolant is hot and under
pressure. Also, hot water or steam is contained in the
engine, radiator and heater lines.
Prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop
position.
Allow all pressure to release before removing the
Fig. 1-24-1
cap.
• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.
Hot fluids and surfaces:

• Skin contact with escaping hot water or steam can
cause severe burns.
Be sure to stop the engine, and let the engine and
radiator cool. Once the system has cooled, slowly
loosen the radiator cap to release pressure, then
remove it.
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts also
become hot.
Fig. 1-24-2
Wait for the oil and components to cool before
starting any maintenance or inspection work.
25 STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious injury
or death.
Securely store attachments and implements to prevent

them falling. Keep playing children and bystanders
away from the storage area.
Fig. 1-25
10
26 DISPOSE OF WASTE PROPERLY
Improper waste disposal can threaten the environment
and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or Fig. 1-26
into any water source.
Allowing air conditioning refrigerants to escape into the

air can damage the Earth's atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
Inquire as to the proper way to recycle or dispose of

waste from your local environmental or recycling
center, or from your HITACHI dealer.
27 SERVICE THE AIR CONDITIONING

SYSTEM SAFELY
Refer to the outside of the freon container for proper
handling procedures when servicing the air
conditioning system.
Use a recovery and recycling system to avoid venting
freon into the atmosphere.
Never let the freon stream make contact with your skin.
Severe frost burns will result.
28 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,
coolants, paint, and adhesives.
Fig. 1-27
11
29 HANDLE POWER WRENCHES
CORRECTLY
Misuse of power wrenches (part nos. 4289389 and
4298388) may lead to their breakage or personal injury.
Please use power wrenches correctly and in
accordance with this manual.
1 For your safety, do not enter into the turning circle

of the wrench. After tightening is complete, a
torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly
let go of the handle, but let it gently rotate back in
the opposite direction until the torque is zero.
Fig. 1-28
2 Excessive input torque may cause the output end

or reaction lever to break, causing the wrench to
fall from the machine. The wrench may also fall if it
slips off the reaction member. Secure the wrench
so that it cannot drop, especially when working on
vertical surfaces.
Fig. 1-29 Fig. 1-30
3 It is sometimes difficult to remove the power

wrench from a nut or bolt after tightening.This is
generally due to elastic deformation (elastic force)
between the wrench and bolt. Try changing the
clutch direction to L to make the wrench easier to
remove. Release the torque on the ratchet handle
gradually, since a force will be acting in the
opposite direction after changing over the clutch. If
it is not possible to change the clutch by hand, do Fig. 1-31
not attempt to use force (a hammer, etc.).
• Try turning the wrench handle slightly in the L

direction to make the clutch easier to change
over.
Fig. 1-32
2
12
30 COMMUNICATION
1 When slinging work is performed on heavy loads, a
predetermined hand signalling method should be
used for trouble-free communication.
2 In order to facilitate remote teamwork during

assembly, workers should wear headsets for
reliable communication.
Fig. 1-33
Fig. 1-34
13
1-2 How to use a power wrench
This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench
should be preferred over a power wrench, for reasons of safety and overall quality.
1 METHOD OF USE 4. Input direction selection on the

ratchet handle.
The input direction is set by using
1. Socket selection and mounting.
the changeover lever on the ratchet
Select the socket which fits most
handle.
snugly onto the bolt, and mount the
socket on the wrench. Secure the
socket to the wrench with a 38.1
Changeover lever
mm pin or 25.4 mm bolt.
Fig. 1-39
5. Changeover clutch.
Changeover
Select the input direction by setting
Fig. 1-35 clutch
the changeover clutch as detailed in
the figure to right (Fig. 1-40).
2. When accurate torque control is

required.
Set the torque according to the
input/output diagram in Fig. 1-49
(page 16). (Output = input x gear
ratio x efficiency)
Fig. 1-40
6. Completion of work.
Fig. 1-36 On completion of tightening,
remove the wrench from the nut or
3. Check the positioning of the reaction lever. bolt. Elastic deformation (force) 2
Depending upon the wrench type the reaction lever usually acts between the wrench and bolt can
radially. Due to the large reaction force applied to the reaction lever, the make it difficult to remove the 1
reaction lever should be positioned so that it is both secure and stable. power wrench. In this case,
gradually release the torque on the
ratchet handle and change over the
clutch direction.
Fig. 1-41
Straight type
reaction lever
Fig. 1-37
When using an "L-type" torque wrench, make sure that the distance "L"
between the center of the bolt and support point is at least the figures
shown below. Failing to observe this minimum distance can damage or
break the bolt, or cause the output shaft to become jammed.
Clutch selection
L (counter clockwise)
L type reaction lever R (clockwise)
Model L
8-150P 110
8-300P 130
12-450P 145
12-600P 160
(Unit: mm)
Fig. 1-38
Fig. 1-42
14
2 THE CORRECT HANDLING OF POWER WRENCHES
Misuse of power wrenches (part nos. 4298389 and 4298388) may lead to their breakage or personal injury. Please use
power wrenches correctly and in accordance with this manual.
CAUTION:
1. Changing the clutch

• Set the base line of the dial to the R or L marker on the power wrench main body.
Base line
(Select R for clockwise, L for counterclockwise movement.)
Yellow A tightening torque is applied with R and a loosening torque with L. Note that reverse
Direction operation may damage the clutch.
Red
• The changeover clutch is intended to prevent reverse rotation when the force is released
during a tightening or loosening operation, and is not designed to transmit torque in the
manner of the ratchet handle.
Ratchet
handle
Fig. 1-43
2. Stay away from the ratchet handle

turning circle.
For your safety, do not enter into the turning circle of the wrench. After
tightening is complete, a torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly let go of the handle,
but let it gently rotate back in the opposite direction until the torque is
zero.
Fig. 1-44
3. Don't drop the wrench.

Excessive input torque may cause the output end or reaction
lever to break, causing the wrench to become removed from
the component. The wrench may also become removed if it
slips off the reaction member. Secure the wrench so that it
cannot fall, especially when working on vertical surfaces.
Fig. 1-45 Fig. 1-46
4. After tightening.
It is sometimes difficult to remove the power wrench from a nut or bolt
after tightening.This is generally due to elastic deformation (elastic
force) between the wrench and bolt. Try changing the clutch direction
to L to make the wrench easier to remove. Release the torque on the
ratchet handle gradually since a force will be acting in the opposite 1
direction after changeover of the clutch. If it is not possible to change
over the clutch by hand, do not attempt to use force (a hammer, etc.).
• Try turning the wrench handle slightly in the

L direction to make the clutch easier to change
over.
Fig. 1-47
Fig. 1-48
2
15
(2548)
5. Power Wrench Input/Output Diagram
Input/Output Diagram (2254)
[Output=input × gear ratio x efficiency]
(1960)
(1666)
Output kgf·m (lbf·ft)

(N.m)
(1372)
(1078)
In selecting a power wrench, give due consideration of the
differences in power performance between the different
(784)
wrench types.
(490)
Input kgf·m
(lbf·ft)
Bolt Power Wrench (N.m) (98) (196) (294) (392) (490) (588) (686) (784) (882)
(6860)
(5880)
(4900)
Fig. 1-49
(3920)
Output kgf·m (lbf·ft)
(N.m)
(2940)
(1960)
Input kgf·m
(lbf·ft)
(N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)
6. Torque Specifications
Bolt Dia Wrench Size Torque

No. Descriptions (mm) (mm) N·m kgf·m lbf·ft
7
1— 16 —12 UNF 41 210 21 154
1 ORS fittings for hydraulic hoses and piping
11
1— 16 —12 UNF 50 350 35 258
2 Cab mounting bolt 16 24 210 21 154
3 Side frame mounting bolt 42 65 4000 400 2950
4 Counterweight mounting bolt 45 65 4000 400 2950
Front pin lock bolt (Backhoe front)
5 A. Front pin lock bolt 20 30 400 40 295
B. Stopper bolt 20 30 400 40 295
Note: *Hexagonal socket wrench
16
1-3 Work precautions
1 APPLYING LUBRICANT
1 Be sure to apply a suitable lubricant to mounting
bolts before tightening. Use lubricant made by
mixing white zinc jelly and spindle oil in 1: 1 White zinc jelly
proportions. Spindle oil
In the case that these materials are not available,
make up the lubricant from materials of the same
composition: 1:1
Material Composition
White zinc jelly Composition list given on page 27
Spindle oil Composition list given on page 27
2 Lubricant should be applied to both the bolt and
spacer, in the positions marked in the diagram Lubricant
below.
Spacer
Bolt Fig. 1-50
Base
Face area Face area Thread of the head
Fig. 1-51
High Tack Adhesive/
2 HANDLING SEALS Sealant #98D
1 Remove the seal fitted to the ports and pipes of

hydraulic components just before assembly, to Fig. 1-52
prevent the ingress of dust.
2 Oil will come out when removing the seals from
the hydraulic ports. Collect it with a suitable oil
container.
3 Lightly apply High Tack Adhesive/Sealant #98D to
the O-ring before hose connection.
Note:
Obtain high tack adhesive/sealant #98D through the
Fig. 1-53
manufacturer detailed on page 27.
3 CONNECTING HOSES
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors.
3 When connecting hoses, do not twist them or their
service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
CAUTION:
Hydraulic ports are sealed with plugs on shipment from
the factory. On removal of these plugs, hydraulic oil will
escape due to the internal hydraulic pressure built up
through transportation, etc.
17
4 BATTERY DISCONNECT SWITCH
This machine is equipped with a battery disconnect
switch b and starter disconnect switch c located
behind the cab.
The battery ground circuit can be disconnected by
turning battery disconnect switch b to OFF position
before replacing the battery, checking the electrical
system, or performing welding work on the machine.
At times such as changing the battery, inspecting or

performing maintenance on the electrical system, or
when welding on the machine, the battery earth circuit
can be cut off by putting battery disconnect switch b in
its OFF position. Similarly, the power supply to just the
starter motor can be cut off by putting starter Fig. 1-54
disconnect switch c in its OFF position.
b
IMPORTANT: OFF
When battery disconnect switch b is turned OFF just

after the key switch is turned OFF, controllers may be
damaged. Wait until DLU indicator a turns OFF. Then
turn battery disconnect switch b to OFF position.
ON
a c
Note: OFF
It takes approximately 5 minutes until DLU indicator

a turns OFF.
ON
Fig. 1-55
Battery Box
18
5 TIGHTENING LARGE-DIAMETER BOLTS
DURING ASSEMBLY.
1 It is vital that large-diameter bolts be tightened to
the specified tightening torque during assembly.
If torque specifications are not followed, the
operation of the machine will be affected, with
machine failure, lowering of functionality and
shortening of machine life potentially resulting. Be
careful, therefore, to note the correct tightening
torque at each stage of assembly.
This manual describes use of a power wrench to Fig. 1-56
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
2 Be sure to tighten each bolt to the specified torque

using a torque wrench, power wrench, or hydraulic
wrench.
Torque wrench
1) After tightening a bolt to the specified torque,
mark the alignment of the bolt head, spacer Fig. 1-57
and bolted part. (See Fig. 1-56.)

2) Use only genuine Hitachi bolts.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) If a bolt is too short, you will not be able to be
tighten it sufficiently to secure the parts, possibly
Pin
resulting in a serious accident.
Moly coat spray
Fig. 1-58
6 NOTES ON INSERTING PINS WHEN
AFFIXING THE FRONT-END ATTACHMENT.
1 When attaching the front-end attachment,
thoroughly clean away the anticorrosive applied to
the pins and pin holes before inserting the pins,
then regrease them and spray them with Moly Pin
coat.
2 Be sure to check the alignment of pin holes when
joining parts. Do not use unreasonable force to
insert pins, and attempt to insert all pins manually.
If this is insufficient, use a medium-sized hammer
to ease the pin in place.
The use of forklift prongs to force in pins is
Fig. 1-59
absolutely forbidden. Any other unreasonable force
can lead to a pin being misformed and rendered
unusable, and should be avoided.
(Fig. 1-59)
7 APPLYING SEALING TAPE.

Wrap sealing tape around the bolt in the opposite
direction to the thread direction.
Do not cover the first two threads, as indicated in Fig.
1-60. Fig. 1-60
19
8 PRECAUTIONS FOR CONNECTING THE PILOT HOSES
Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying
attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants
may cause the pilot valve to malfunction.
Plug
Plug
Step 1 The ends of both the valve and hose to be

connected will be sealed with plugs.
Detail A
Fig. 1-61
Adaptor
Step 2 1) Remove the plugs. Fitting

2) Thoroughly clean the hose fitting and
adaptor, then connect them, taking care Remove
the plugs
to prevent the ingression of any
contaminants.
Detail B
Fig. 1-62
Adaptor

Step 3 Connect the adaptor and hose fitting.
Fitting
Notes:
i) When connecting hoses, do not twist
them, or their service life will be
shortened.
ii) Connect the hoses so as to avoid
contact with other parts. Detail C
Fig. 1-63
iii) Make sure that no dust has adhered to
the seat face of the hoses.
iv) Be careful to not damage the joining
surfaces of the hoses.
20
9 Standards for Hydraulic Joint Work
A ORS joint
Work procedure
1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Check for dirt and scars
Adapter Hose, union part
O-ring Fig. 1-64
2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand
98D (Loctite, Ltd) to the screw part of the hose union.
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Press the entire O-ring with your fingers and install it properly.
iii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic
circuit, causing a breakdown.)
Handle the O-ring with your bare hands!
Apply spray grease here. Fig. 1-65
3 Screw the hose and union into the adapter.
Notes:
i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the
hose horizontal to each other to keep them immobile.
ii) Tighten the union nut fully with your hands.
iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will
not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality,
loosen the union nut and make sure to verify the O-ring.
Tighten the union nut fully with your hands
Fig. 1-66
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Note:
After the work, carry out a check using a white pen.
21
B Union joint
Work procedure
1 Check that the adapter and hose union seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Adapter seat surfaces Hose union seat surface
Fig. 1-67
Fig. 1-68
Apply spray grease here
2 Apply spray grease to the screw parts of the hose and union.
Note:
Do not overapply.
(When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil leak.)
3 Screw the hose into the adapter.
Note:
Tighten fully using your hands.
(If there are no scars on the thread, you will be able to screw it fully with your hands.)
Tighten the union nut fully with

your hands
Fig. 1-69
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Notes:
i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it.
ii) After the work, carry out a check using a white pen.
22
C Split flange joint
Work procedure
1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.
Notes:
i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt.
Check for scars and dirt Fig. 1-70
O-ring Hose, flange
2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D
(Loctite, Ltd).
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Apply the bond uniformly to the groove. Do not overapply.
(Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.)
iii) Press the entire O-ring with your fingers and install it properly.
Handle the O-ring with your bare

hands. Do not overapply the bond. Fig. 1-71
3 Installing the split flange
1) Temporarily install one side of the split flange 2) Confirm the O-ring and set the hose onto the
using the socket bolts. split flange.
Note: Notes:
Using your hands, screw in the bolt to about half its i) Make sure to insert the hose horizontally to the
length. installation surface.
ii) Take care so that the O-ring does not fall out of
place.
Screw in the bolt to

about half its length.
Pay attention to
the O-ring
Fig. 1-72 Fig. 1-73
Split flange Socket bolts
23
3) After setting the hose, install the other split flange.
Notes:
i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-ring
may fall off.
ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.
Install other split flange

If the bolt has not been
screwed in adequately,
the instability of the hose
seat surface will increase,
causing the O-ring to fall
Fig. 1-74 off
Fig. 1-75
4 Tightening the socket bolt
1) Temporary tightening, hose angle adjustment 2) Tightening the bolts

• Make sure to tighten the bolts in the correct • Tighten the bolts using a crisscross
order to avoid lopsided tightening. sequence in the same way as for temporary
• The bolts should be tightened using a tightening.
crisscross sequence. • Be careful not to tighten the bolts lopsidedly.
• The hose should still have movement even • Be careful not to overtighten the bolts with
after the bolts have been tightened. an impact wrench.
• Adjust the hose angle.
3) Checking the torque
1 4 • Use a torque wrench to check that the bolts
are properly tightened.
• Check the bolts in the same crisscross
Bolt tightening sequence sequence as for tightening.
• After the work, carry out a check using a
white pen.
3 2
Fig. 1-76
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-77 Fig. 1-78
24
10 ADJUSTING LIFTING ANGLE
Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever
block) connecting the wire ropes, the lifted angle of the
load can easily be adjusted.
Wire rope
Wire rope
L'
Chain block
(Lever block)
Chain block
Wire rope
Lever block
Fig. 1-79
Work
Example
The angle of the workpiece in Fig. 1-80 can be
adjusted using chain blocks A .
Workpiece
Chain block
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-80
25
11 CAUTIONARY REMARKS FOR ASSEMBLY
1 Machine warning during non-installation of urea-related parts (tampering)
There are some problems that can occur when urea-related parts are not installed. For example, the monitor can
display the urea SCR system failure icon, restricting engine output and rotation. This can happen when the NOx
sensor controller and SCR exhaust air temperature sensor controller of the urea SCR muffler unit are not
connected to a harness or else, when the machine is left in the key-ON state for a certain time without connecting
the urea hose to the dodging module. The real engine rotation will not be as explained in the engine control dial
instructions, but this is not a failure. Connect the above parts. The engine output and rotation restriction will be
released after about twenty minutes in the key-ON state. If the connection of the parts does not release the engine
output and rotation restriction, inquire with the closest Hitachi dealer.
2 Display of the post-treatment device regeneration request (cleaning mode)
If the machine is operated at low idle for a long time, the monitor might display a request for post-treatment device
regeneration. If that happens, immediately implement the cleaning mode. For more information, refer to the
operation manual.
26
12 FOR REFERENCE
1 Ingredients of the white zinc jelly and spindle oil.
White zinc jelly
This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil.
Ingredients: Extender pigment (calcium carbonate): 84.0%
Color pigment (titanium oxide): 0.5%
Fatty oil (polymerized oil): 14.0%
Solvent (mineral turpentine): 1.5%
Spindle oil
Physical and chemical properties of this oil are as follows. (grade C machine oil)
Appearance: Light brown
Flash point (COC): Above 160°C (320°F)
3
Density: 0.89 ~ 0.95 g/cm
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
2 Purchase high tack adhesive/sealant #98D from the following company:
Company Name: Loctite, Ltd.

Part Name: High Tack Adhesive/Sealant #98D
Part No.: 80063 (Loctite Part No.)
13 READ THE OPERATION MANUAL

Read the operation manual and this assembly
procedure manual thoroughly to familiarize yourself
with the work procedure.
Fig. 81
27
28
2. Workers plan (Backhoe front)
This plan varies depending on jobsite environment, working conditions, assembly facilities, tools, and worker’s skill.
Days 1
day
2
day
Weather fine
40 t×1 day
Cranes
(With operator and assistant)
40 ton nes 40 t×1.5 day
(44 US tons)
1 unit×0.5 day
Scaffolding
Tool check
Unloading
Unpacking major component

PREPARATION
parts
Checking parts
Cleaning parts
Assembly of side frame and

track frame (upperstructure)
Workers
Foreman,
Assembly of upperstructure
and three
(Install of fenders, handrails and ladders)
assistant
workers ×
2.0 days
Assembly of backhoe front

ASSEMBLY
Assembly of counterweight
Mounting of bucket
· Greasing
· Refrigerant (gas) quantity
· Track link tension
Adjusting OPERATION
Repainting
Complete assembly check
29
2-1 Transportation (Backhoe front)
3
3
Example: Backhoe front (Unit: metric ton)
1 2 3 4 5
· Boom assembly Handrails,

Upperstructure Side frame CounterWeight
· Arm assembly ladders, step
(Left & Right)
· Bucket assembly and etc.
· Boom cylinder×2
40-tonne 40t
trailer
35-tonne 35t
trailer
Trailers and trucks
30-tonne 30t
trailer
20-tonne 20t
trailer
15-tonne 15t
truck
30
TRANSPORTATION
Unit: mm (ft in)
PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION BASE MACHINE
Base Machine (Low-cab)

Backhoe
Weight : 39 200 kg (86 420 lb)
(11'7")
(11'4")
(10'11")
(14'1")
(15'8")
(22'8")
Width : 3 500 mm (11' 9")
Counterweight Washers and Bolts ~ 10

Weight : 18 000 kg (39 682 lb) Weight : 7.1 kg (16 lb)
(3'0")
ø90
(0'4")
(0'1")
23
(5'11")
(1'10")
576
Width : 3 500 mm (11' 6")
31
TRANSPORTATION
Unit: mm (ft in)
UNDERCARRIAGE
Side frame (L) Washers and Bolts ~ 52
Side frame (R) Weight : 5 kg (11 lb)
25 mm
216 mm Weight: 2.61 kg (5.8 lb)
80 mm Weight: 2.24 kg (4.9 lb)
ø 80 mm
STD track Full track
guard guard
700G shoe
900G shoe
Ladders ~ 2 Cover (R) ~ 1 / Cover (L) ~ 1

700 mm shoe-use Weight : 25 kg (55 lb)
Weight : 20 kg (44 lb)
640
(2'1")
937 (3'1")
(2'8")
807
645
(2'1")
Width : 302 mm (12") Width : 258 mm (10")
32
TRANSPORTATION
Unit: mm (ft in)
LEFT SIDE OF BASE MACHINE

Fender Fender
Fender next to the cab Fender next to the hydraulic oil tank
Weight : 254 kg (560 lb) Weight : 131 kg (289 lb)
(4'8")
(4'8")
(7'11") (6'6")
Width : 1 030 mm (3'5") Width : 832 mm (2'9")
Fender Step Ladder

Fender next to the pump Weight : 19.5 kg (42.9 lb) Weight : 462 kg (1 019 lb)
Weight : 84.6 kg (187 lb)
(1'1")
(7'2")
(3'8")
(4'8")
(1'0")
(3'7")
(3'10")
Width : 625 mm (2'1") Width : 980 mm (3'3")
Chain Handrail Mirror;Assy

Weight : 0.4 kg (0.9 lb) Weight : 1.55 kg (3.4 lb) Weight : 1.77 kg (3.9 lb)
(0'4")
337
(1'1")
(1'2")
(1'10")
362
(1'10")
Width : 43 mm (1.7") Width : 101 mm (4")
Handrail Handrail
Weight : 15.8 kg (34.8 lb) Weight : 11.9 kg (26.2 lb)
Washer
Bolt
Bolt assembly for the

fender installation~10
(3'5")
(3'4")
Washer
Bolt
Bolt assembly for the

fender installation~12
Washer
Bolt
(3'4") (2'1") Bolt assembly for the

ladder installation~6
Width : 577 mm (1'11") Width : 530 mm (1'9")
33
TRANSPORTATION
Unit: mm (ft in)
RIGHT SIDE OF BASE MACHINE

Fender Handrail Handrail
Weight : 174 kg (384 lb) Weight : 12.3 kg (27 lb) Weight : 27.7 kg (61 lb)
Width : 834 mm (2'9") Width : 267 mm (11") Width : 637 mm (2'1")
Handrail Step Hose real

Weight : 7.35 kg (16.2 lb) Weight : 3.58 kg (7.9 lb) Weight : 33.8 kg (75 lb)
400
155
782
547
1020
560
50
Width : 50 mm (2") Width : 265 mm (10.4")
Duct assembly Bolt assembly ~ 8 Duct assembly

Duct assembly in front of radiator Duct assembly in front of oil cooler
Weight : 75.6 kg (167 lb) Weight : 75.4 kg (166 lb)
(Washer, plain 4338575)

(Bolt J901495)
Duct mounting
bolt, assembly - 8
Bolt assembly ~ 4
(Washer, plain 4338575)

(Bolt J901435)
Duct assembly hinge mounting
sems bolt - 4
Width : 75 mm (3") Width : 75 mm (3")
34
TRANSPORTATION
Unit: mm (ft in)
BASE MACHINE
SCR Muffer cover SCR Muffer cover SCR Muffer cover
300
183
532
470 1095
545
Width : 60 mm (2.4") Width : 80 mm (3.2") Width : 90 mm (3.5")
SCR Muffer cover SCR Muffer cover SCR Muffer cover

Weight : 4.73 kg (10.4 lb) Weight : 22.9 kg (50.4lb) Weight : 29.4 kg (64.8 lb)
532
645
765
545
908 908
Width : 138 mm (5.4") Width : 495 mm (1'7) Width : 765 mm (2'6")
SCR Muffer covers ~ 2 SCR Muffer cover SCR Muffer cover SCR Muffer cover
Weight : 18.9 kg (41.6 lb) Weight : 4.95 kg (11 lb) Weight : 5.27 kg (11.6 lb) Weight : 1.12 kg (2.4 lb)
306
306
510
40
450
495 645
905
Width : 545 mm (2') Width : 155 mm (6") Width : 155 mm (6") Width : 40 mm (1.5")
SCR Muffer cover SCR Muffer cover Weight SCR Muffer cover SCR Muffer cover
Weight : 0.85 kg (1.9 lb) : 1.33 kg (2.9 lb) Weight : 0.85 kg (1.9 lb) Weight : 0.15 kg (0.33 lb)
65
40
315
40
290
40
530
40
Width : 40 mm (1.5") Width : 40 mm (1.5") Width : 40 mm (1.5") Width : 40 mm (1.5")
35
TRANSPORTATION
Unit: mm (ft in)
BASE MACHINE
Ejector Exhaust pipe Exhaust plumbing fixed bracket Gasket
Weight : 15 kg (33 lb) Weight : 46.6 kg (103 lb) Weight : 11.1 kg (24.4 lb) Gasket for exhaust laying
pipes installation
Gasket for the ejector installation

Weight : 1.2 kg (2.6 lb)
Width : 343 mm (1'2") Width : 324 mm (1'0.8") Width : 2 mm (0.1")
U-Bolt assembly Mirror assembly Mirror assembly Mirror assembly

Weight : 0.82 kg (1.8 lb) Weight : 2.49 kg (5.5 lb) Weight : 2.07 kg (4.6 lb) Weight : 1.93 kg (4.3 lb)
Width : 26 mm (1") Width : 125 mm (4.9") Width : 157 mm (6.2") Width : 132 mm (5.2")
Mirror assembly Camera Antenna Wiper assembly ~ 2

Width : 125 mm (4.9")
Lamp assembly Lamp assembly Rear lights ~ 2 Brackets ~ 2 Brackets ~ 2

Weight : 1.0 kg (2.2 lb) Weight : 1.1 kg (2.4 lb) Weight : 0.5 kg (1.1 lb) Weight : 0.22 kg (0.5 lb) Weight : 1.0 kg (2.2 lb)
Width : 87 mm (3.4")
36
TRANSPORTATION
Unit: mm (ft in)
BASE MACHINE
Rear camera harness Rear camera harness

Weight : 1.0 kg (2.2 lb) Weight : 0.5 kg (1.1 lb)
BASE MACHINE (SCR drain pipe)

Pipe Pipe Assem Pipe
Width : 51 mm (2") Width : 64 mm (2.5") Width : 65 mm (2.6")
Pipe Tube: Plastic Pipe

Weight : 0.54 kg (1.2 lb)
(3.9")
(11")
Width : 51 mm (2")
Tube: Plastic Option

WIU Antenna
Weight : 0.07 kg (0.15 lb)
37
TRANSPORTATION
Unit: mm (ft in)
BACKHOE ATTACHMENT
Boom
Boom length A B Width Weigh

7.55 m 7 960 mm 3 450 mm 1 580 mm 11 800 kg
BE-Boom
(24'9") (16'3") (11'4") (5'2") (26 014 lb)
Arm
Arm
A B Width Weigh
length
B
3.4 m 4 940 mm 1 990 mm 1 110 mm 6 750 kg
BE-Arm
(11'2") (16'3") (6'6") (3'8") (14 881 lb)
Boom cylinders ~ 2 Lamp:head

Weight : 1 130 kg (2 491 lb) Weight : 1.17 kg (2.57 lb)
450
204
ø356
3490
205
Width : 356 mm (1' 2")
Width : 110 mm (4")
Backhoe Bucket
Capacity
A B Width Weigh
PCSA heaped B
3
7.0 m 2 830 mm 2 330 mm 2 640 mm 7 860 kg
(9.15 yd3) (9'4") (7'4") (8'8") (17 328 lb)
38
TRANSPORTATION
Unit: mm (ft in)
Option Aerial Angle
Skyangle Cameras ~ 4 Covers ~ 4 Brackets ~ 4

44 37
46
550
Width : 63 mm (2.5") Width : 51 mm (2")
Bracket Bracket Bracket Bracket

Width : 134 mm (5.3") Width : 182 mm (7.2") Width : 370 mm (1’2.6") Width : 140 mm (5.5")
39
NOTES
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................... ............. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . .. . . . . . . . . ............................... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .......................................................................................... .. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
40
3. Parts check
3-1 Check
1 Unpack the major component parts.
2 Check their quantity against that shown on the packing

list.
3 Check the parts for any damage during transportation.

If there are any missing or damaged parts, take
pictures of the damage and then contact Hitachi or your
Hitachi distributor as soon as possible.
Fig. 3-1
41
4. Preparations (Backhoe front)
1 Work site: Select a place where the ground is firm 3 Cranes: Prepare two 40 tonne (44 US ton) cranes.
and flat.
2 Space: Secure a space of 13 m (43 ft) × 23 m (75 4 Arrangement of major components: See Figs. 4-1,
ft) or more. 4-2 and 4-3 below.
Weight Crane
1 Basic machine assembly 39 200 kg ( 86 420 lb) 12 A
2 Fenders,handrails and ladders 1 181 kg ( 2 603 lb) 13 B
3 Side cover (radiator) 75.5 kg ( 166 lb)
4 Side cover (oil cooler) 75.3 kg ( 166 lb)
Wt (kg)/lb
STD track Full track

5 Side frame assembly (left) guard guard
6 Side frame assembly (right) 700G shoe
15 200 kg 15 600 kg
(33 510 lb) (34 392 lb)
15 900 kg 16 300 kg
900G shoe
(35 053 lb) (35 935 lb)
7 Counterweight 18 000 kg ( 39 682 lb)

8 Boom assembly For BE boom 11 800 kg ( 25 573 lb)
9 Boom cylinders 1 130 kg ( 2 491 lb) ×2
10 Arm assembly For BE arm 6 540 kg ( 14 418 lb)
11 Bucket assembly For 7.0 m3 7 860 kg ( 17 328 lb)
12
11 6
8
1 7
2 -a
10
2 -b
2 -c 5
3 4
13
9
Fig. 4-1
42
Unit: mm (ft.in) Unit: kg (lb)
A B Width Weight
16 130 mm 5 770 mm 5 470 mm 116 000 kg

EX1200-7B STD.
(52' 11") (18' 11") (17' 11") (255 734 lb)
14 740 mm 5 970 mm 5 470 mm 118 000 kg
EX1200-7B BE-front
(48' 4") (19' 7") (17' 11") (260 143 lb)
BACKHOE
A
Fig. 4-3
Fig. 4-2
43
NOTES
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................... ............. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . .. . . . . . . . . ............................... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .......................................................................................... .. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
44
5. Machines, apparatus, tools, and materials necessary for assembly
Listed below are the machines, apparatuses tools and materials required for assembling the EX1200-7B hydraulic
excavator.
1 Cranes
Two cranes of 40 tonnes (44 US tons)
2 Wire ropes
8 mmø × 3 000 mm (L) - 4 pcs.
(0.3 in) (117 in)
8 mmø × 5 000 mm (L) - 4 pcs.
(0.3 in) (195 in)
10 mmø × 2 000 mm (L) - 2 pcs.
(0.4 in) (78 in)
10 mmø × 3 000 mm (L) - 4 pcs.
(0.4 in) (117 in)
10 mmø × 5 000 mm (L) - 2 pcs.
(0.4 in) (195 in)
22 mmø × 3 000 mm (L) - 4 pcs.
(0.85 in) (117 in)
22 mmø × 10 000 mm (L) - 2 pcs.
(0.85 in) (390 in)
26 mmø × 2 000 mm (L) - 2 pcs.
(1.0 in) (78 in)
24 mmø × 5 000 mm (L) - 4 pcs.
(0.95 in) (195 in)
26 mmø × 3 000 mm (L) - 2 pcs.
(1.0 in) (117 in)
26 mmø × 8 000 mm (L) - 3 pcs.
(1.0 in) (312 in)
36 mmø × 8 000 mm (L) - 1 pc.
(1.4 in) (312 in)
36 mmø × 10 000 mm (L) - 1 pc.
(1.4 in) (390 in)
3 Nylon sling belts

100 mm (W) × 2 000 mm (L) - 2 pcs. 20 mm (W) × 4 000 mm (L) - 2 pcs.
(4.0 in) (78 in) (0.8 in) (156 in)
4 Shackles
For 1-ton load - 2 pcs. For 5-ton load - 4 pcs. For 10-ton load - 2 pcs.
5 Chain blocks or lever blocks:

For 2-ton load - 2 pcs. For 2-ton load - 2 pcs. Lever blocks
Chain blocks
For 10-ton load - 1 pc.
Note:
There are some methods of centering the work by
the chain block or lever block.
Refer to 10 on page 25 as an example.
45
6 Wooden blocks
1 200 mm (L) × 800 mm (W) × 1 000 mm (H) - 2 pcs. 1 000 mm (L) × 500 mm (W) × 800 mm (H) - 2 pcs.
(49 in) (30 in) (40 in) (40 in) (20 in) (30 in)
1 500 mm (L) × 300 mm (W) × 200 mm (H) - 1 pc.

(59 in) (12 in) (8 in)
7 Scaffolding
2 pcs.
8 Oil containers
20 liter capacity - 4 pcs. 10 liter capacity - 2 pcs.
9 Standard tools
Prepare 4 or more sets.
10 Touch-up paint
11 Air impact wrenches (with air compressor)

400 kgf·m capacity - 1 pc. 20 kgf·m capacity - 1 pc.
(3 920 N·m/2 890 lb·ft) (195 N·m/145 lb·ft)
12 Hydraulic jacks
20-ton load - 2 pcs.
13 Protectors and patches Protectors
Example of protector (see Fig. 5-1)

Used tire
14 Hand tachometer or digital tachometer

Pulse meter Adapter Engine speed sensor
15 Torque wrench
34 ~ 882 N·m capacity
(3 ~ 90 kgf·m/25 ~ 651 Ib·ft)
Number of protectors made: 10 pcs.
16 Safety life lines - 4 sets Fig. 5-1
17 Grinder
18 Halide torch or electric leak detector

Used to detect leakage of refrigerant gas.
19 Bar-type thermometer - 1 pc. 22 Miscellaneous

Used to measure refrigerant temperature. Rags
−10 ~ 100°C crange Cleaning detergent
(50 ~ 212°F) Lubricant
Light & cord reel for work
20 Pressure gauge - 1 pc. Grease
200 kg/cm2 capacity Moly coat spray
21 Ropes 23 Special tools (refer to following page)

8 mmø × 5 000 mm (L) - 2 pcs. For the tools which are not available locally,
(0.3 inø) (195 in L) place order to Hitachi in advance.
46
Note:
For the tools which are not available locally,
SPECIAL TOOLS Kit No. 915707 place order to Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Tap to be screwed
1 4395305 1 in bolt hole for
Tap tighening the
side frame
Fig. 5-2
4093798
Torque wrench
100 ~ 410 N·m Used to tighten
2 10 ~ 42 kgf·m 1
the bolts.
74 ~ 302 lbf·ft
capacity
Fig. 5-3
4093800
Used to tighten
Power wrench
3 1 the side frame
With wrench, socket
to track frame
P/No. 4298389
Max. output torque

4 410 N·m (450 kgf·m/3 253 lbf·ft) Fig. 5-4
4229414 Used to tighten

4 Power wrench 1 the side frame
With wrench, socket to track frame
P/No. 4298388
Max. output torque

3 430 N·m (350 kgf·m/2 530 lbf·ft) Fig. 5-5
47
Note:
For the tools which are not available locally,
SPECIAL TOOLS (Others) place order to Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Vacuum pump
Assembly ST6905
Used to create
5 Vacuum pump ST6440 1 set vacuum in the
Hose ST6326 hydraulic tank
Nipple PT 1/8 ST6066
Nipple PT 3/8 ST6068
Fig. 5-6
90˚ 2 45˚
(20)
Section A 15˚ 30˚

16
6 Bar 1 For use with

item no. 3
ø30
16
(820)
R8 50
R15 50 (50)
ø10
5
5
R36
Fig. 5-7
40
ø12
M20×2.5
For removing /
7 Pin removal/ inserting the various
7 1
front-end attachment
insertion jig
pins
17 Fig. 5-8
Directions for use of the pin removal/insertion jig
Pin removal Pin insertion
Item no. 7 Item no. 6

Fig. 5-9
48
EX1200-7B Assembly Manual
UPPERSTRUCTURE
ASSEMBLY OF UPPERSTRUCTURE
6. Assembly of upperstructure
6-1 Preparations
ASSEMBLY CHART OF UPPERSTRUCTURE

Backhoe-Front
Fig. 1
51
Step 1
1 Parts required/procedure XF60005133 (Backhoe-front)

1/3
Item Part No. Part name Q'ty Weight: kg (lb) Remarks
00 XF10014945 Upper, Machinery 1 39200.00 (86420.00)
02 YA40033741 Weight, Counter 1 18000.00 (39683.00)
03 YA00048666 Bolt 10 6.24 (13.76)
04 YA00048667 Washer 10 0.878 (1.94)
06 XF10014946 Frame, Side (L) 1 15600.00 (34392.00)
07 XF10014947 Frame, Side (R) 1 15600.00 (34392.00)
08 J834214 Bolt 52 2.610 (5.75)
09 4244330 Spacer 52 2.240 (4.94)
10 YA40027152 Ladder 1 20.80 (45.85)
11 7059399 Cover 1 24.90 (54.90)
12 7059400 Cover 1 24.90 (54.90)
14 XF10014948 Assy, Duct (RAD) 1 75.60 (166.67) Duct assembly in front of radiator
15 XF10014949 Assy, Duct (O/C) 1 75.40 (166.23) Duct assembly in front of oil cooler
16 XF10014950 Assy, Bolt 8 0.16 (0.35)
17 XF10014951 Assy, Bolt 4 0.10 (0.22)
20 XF10014987 Assy, Bolt 10 0.14 (0.31)
21 XF10014988 Assy, Bolt 12 0.12 (0.27)
22 XF10014989 Assy, Bolt 6 0.14 (0.31)
24 XF10014985 Assy, Fender 1 84.60 (186.51)
25 XF10014986 Assy, Fender 1 131.00 (288.80)
27 XF10014984 Assy, Ladder 1 462.00 (1018.53)
28 4322539 Spacer 1 0.030 (0.07)
29 YA00049110 Clip 1 0.015 (0.03)
30 J271045 Bolt, Sems 1 0.015 (0.03)
31 4336875 Braket 1 0.010 (0.22)
32 J271025 Bolt, Sems 1 0.030 (0.07)
34 YA40033346 Handrail 1 15.80 (34.83)
35 YA40034257 Handrail 1 11.90 (26.24)
37 XF10014955 Assy, Fender 1 254.00 (559.97)
38 XF10014956 Assy, Mirror 1 2.490 (5.49)
39 XF10015232 Assy, Mirror 1 1.770 (3.90)
40 XF10014957 Handrail 1 1.550 (3.42)
41 XF10015234 Assy, Mirror 1 2.070 (4.56)
42 XF10014958 Assy, Lamp 1 1.000 (2.21)
43 XF10014959 Antenna 1 0.200 (0.44)
44 YA40033591 Step 1 19.50 (42.99)
45 4401490 Chain 1 0.40 (0.88)
49 XF10014960 Assy, Fender 1 174.00 (383.60)
50 XF10014961 Assy, Hose-Reel 1 33.80 (74.52)
51 YA00015760 Lamp, Working 1 1.100 (2.43)
52 YA00049110 Clip 4 0.015 (0.03)
53 J271025 Bolt, Sems 5 0.030 (0.07)
54 4448037 Bracket 1 0.020 (0.04)
55 XF10014962 Assy, Mirror 1 2.890 (6.37)
56 8083483 Step 1 3.580 (7.89)
57 XF10015233 Assy, Mirror 1 1.930 (4.30)
52
2/3
59 YA40033734 Handrail 1 12.30 (27.12)
60 YA40038476 Handrail 1 27.700 (61.07)
61 YA40034140 Handrail 1 7.350 (16.20)
65 YA60018849 Camera, Assy 1 2.340 (5.16)
66 J271020 Bolt, Sems 4 0.030 (0.07)
67 4274478 Lamp, Head 2 0.500 (1.10)
68 8104656 Bracket 2 0.220 (0.49)
69 3110958 Bracket 2 1.000 (2.21)
70 J271230 Bolt, Sems 2 0.050 (0.11)
71 4259220 Clip, Band 2 0.010 (0.02)
72 J271225 Bolt, Sems 4 0.040 (0.09)
73 4712344 Harness, Wire 1 0.500 (1.10)
74 YA00052040 Harness, Wire 1 1.000 (2.21)
75 YA00049110 Clip 5 0.015 (0.03)
76 J271220 Bolt, Sems 7 0.040 (0.09)
77 4055312 Clip, Band 3 0.010 (0.02)
78 YA00049114 Clip 6 0.018 (0.04)
79 J271025 Bolt, Sems 2 0.030 (0.07)
81 XF10015389 Handle 1 0.100 (0.22)
89 YA00056746 Ejector 1 15.000 (33.07)
90 4605479 Gasket 1 1.200 (2.65)
91 XF10014990 Gasket 1 0.010 (0.02)
92 XF10014964 Assy, Exhaust 1 46.600 (102.73)
93 XF10014965 Assy, Bracket 1 11.100 (24.47)
94 J281230 Bolt, Sems 4 0.060 (0.13)
95 XF10014966 Assy, U-Bolt 2 0.820 (1.81)
96 4297136 Tube, Plastic 1 0.030 (0.07)
97 YA00056338 Pipe 1 0.286 (0.63)
98 4269767 Tube, Plastic 1 0.020 (0.04)
99 4508575 Clamp, Hose 3 0.010 (0.02)
100 4344303 Clip 1 0.010 (0.02)
101 YA00048616 Clip, Hose 3 0.010 (0.02)
102 J271025 Bolt, Sems 4 0.030 (0.07)
103 4619811 Hose 1 0.220 (0.49)
104 4504199 Clamp, Hose 2 0.010 (0.02)
105 YA00028916 Pipe 1 3.670 (8.09)
106 XF10014967 Assy, Pipe 1 0.951 (2.10)
107 YA00045817 Pipe 1 0.542 (1.20)
109 YA40034336 Cover 1 3.070 (6.77)
110 YA40036297 Cover 1 4.260 (9.39)
111 YA00049154 Cover 1 4.270 (9.14)
112 YA40034695 Cover 1 4.730 (10.43)
113 YA40034334 Cover 1 22.900 (50.49)
114 YA40034335 Cover 1 29.400 (64.82)
115 YA60049451 Cover 2 18.900 (41.67)
116 YA60049466 Cover 1 4.950 (10.91)
117 YA60049467 Cover 1 5.270 (11.62)
53
3/3
118 YA00049141 Bracket 1 1.120 (2.47)
119 YA40036307 Bracket 1 0.848 (1.87)
120 YA00049143 Bracket 1 1.330 (2.93)
121 YA40036334 Bracket 1 0.854 (1.88)
122 YA00049146 Bracket 1 0.149 (0.33)
123 J271030 Bolt, Sems 20 0.030 (0.07)
124 J271225 Bolt, Sems 10 0.040 (0.09)
125 J281035 Bolt, Sems 54 0.040 (0.09)
130 9768598 Bracket 2 0.150 (0.33)
131 YA00049222 Clip 3 0.037 (0.08)
132 J271025 Bolt, Sems 5 0.030 (0.07)
2 Packing Waiper: XF60004556
00 XF10013411 Waiper assembly 2 0.6 (1.32)
3 Packing WIU Antenna (option): XF60005110
00 YA00003967 Antenna 1 0.07 (0.15)
54
4 Procedure Packing Aerial Angle XF60005122

00 YA60035875 Skyangle, Camera 4 0.290 (0.639)
01 YA40018662 Cover 4 0.120 (0.265)
02 YA00039445 Bracket 4 0.132 (0.291)
06 J217083 Washer 8 0.020 (0.044)
07 J950010 Nut 8 0.010 (0.022)
08 YA40034344 Bracket 1 3.700 (8.157)
09 YA40034345 Bracket 1 3.780 (8.333)
10 YA40034325 Bracket 1 3.340 (7.363)
11 YA40034326 Bracket 1 1.540 (3.395)
13 4190126 Clamp, Pipe 3 0.280 (0.617)
14 4190127 Clamp, Pipe 3 0.440 (0.970)
19 YA00049110 Clip 25 0.015 (0.033)
22 4382432 Spacer 6 0.030 (0.066)
23 J271025 Bolt, Sems 14 0.030 (0.066)
24 J271030 Bolt, Sems 1 0.030 (0.066)
26 J271225 Bolt, Sems 2 0.040 (0.088)
27 J271255 Bolt, Sems 6 0.070 (0.154)
28 J271260 Bolt, Sems 1 0.070 (0.154)
29 J271265 Bolt, Sems 3 0.070 (0.154)
30 4055312 Clip, Band 10 0.010 (0.022)
31 4205136 Bushing, Rubber 1 0.010 (0.022)
32 J271055 Bolt, Sems 2 0.050 (0.110)
34 4407522 Spacer 8 0.030 (0.066)
35 J281055 Bolt, Sems 8 0.060 (0.132)
36 YA00028068 Rubber, Cushion 8 0.020 (0.044)
37 YA00049118 Clip 4 0.020 (0.044)
39 YA00056150 Spacer 8 0.030 (0.066)
55
56
6-2 Connection of upperstructure and side frames
Step 1 Lift
Preparation of the side frame assembly (left)
1 Lift the side frame assembly (left) 06 as illustrated in

Fig. 1.
Wire ropes
26 mmø × 8 000 mm
Note:
Apply protectors at 12 points a , b and c , indicated
by to prevent the wire ropes from breaking.
Side frame (700G) 06 weight: 15 200 kg (33 510 lb)

Side frame (900G) 06 weight: 15 900 kg (35 053 lb) a
b 06
Wire rope: 2 pcs.
26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L)
Front side Fig. 1
c
Protector: 12 pcs.
2 Put the side frame assembly on the ground to set the

travel device backward.
CAUTION:
Never allow any persons to stand directly beneath the
Rear side
lifted side frame. Travel Device
Fig. 2
Detail A
3 Cleaning and finishing
1 Clean all screw holes on the side frame using a tap d

(indicated by in d Fig .3).
Tap size: M42×3
2 Clean the front and rear surfaces (indicated

Fig. 3
by e in Fig. 4) of the side frame.
3 Check the surfaces for damage or scratches. Detail B
e
Note:
If they are damaged, repair and/or refinish them.
Fig. 4
57
Step 2
Wire rope handling work of the Upperstructure 00
Note:
The instructions given below are applicable to the
side frame connection for the low cab-use
upperstructure. The same instructions will be
applied for the high cab-use uppperstructue.
Detail C
1 Prepare two 40 tonne (44 US ton) cranes for lifting Wire ropes at front side Fig. 5
the upperstructure assembly 00 . Lift Wire rope
26 mmø ×
2 Attach wire ropes to the upperstructure assembly Wire rope
8 000 mm
illustrated in Figs. 6 and 7. 26 mmø × Detail D

2 000 mm
1 Wire ropes and chain block at the front side of the Wire ropes at rear side
Chain Wire rope Lift
upperstructure.
block 36 mmø ×
Apply the protectors and wooden block a to the 5 000 mm
pins as shown in Figs. 6-a and 6-b.
Wire rope
Fig. 6-b 36 mmø ×
2 Wire ropes at the rear side of Wooden block a
5 000 mm
the upperstructure. Protector
Apply the protectors to the
beam of the main frame as
shown in Figs. 7-a and 7-b.
Left side
Upperstructure assembly 00
Weight: 39 200 kg Wire rope
(Low-cab/High-cab) (86 420 lb) 26 mmø ×
2 000 mm
Wire rope: 1 pc. 26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L)
Protectors
Wire ropes: 2 pcs. 26 mmø × 2 000 mm (L)
(1.0 inø) (78 in L) Fig. 6-a
Wire rope: 2 pc. 36 mmø × 5 000 mm (L) Fig. 7-a Shackle

(1.4 inø) (195 in L)
Lift
Lift
Protector: 6 pcs.
Chain block: 1 pc. for 10 tonne (11.0 US ton) load Fig. 7-b
Wooden block a :1 pc.
Shackle: 2 pcs. 15 tonne (16.0 US Ton) load
3 Lift the upperstructure assembly horizontally as

illustrated in Fig. 8.
Rope
Notes:
i) Level the upperstructure by adjusting the preset Hold
chain blocks.
Rope
ii) It is safe to attach a rope on the sections
indicated by in order to guide it.
Hold
Rope: 2 pcs. 10 mmø × 5 000 mm (L)
Fig. 8
(0.4 inø) (195 in L)
CAUTION:
CAUTION: When doing the joining work of the side frame, station
i) Be sure to use the protectors to prevent the wire the sub-leaders each at the front and rear locations of
ropes from breaking. (Fig. 6 and 7) the upperstructure to do the work following the signs of
ii) Never allow anyone to stand directly beneath the the leader with utmost care so as not to break the
lifted machine. component parts.
58
Step 3
Lift
Preparation of the track frame
1 Positioning side frame

Lift
While lifting the upperstructure assembly with a crane,
turn the track frame at 90°. The side frame is
assembled at the bottom of the upperstructure.
Notes:
i) To position the side frame, the upperstructure
must be turned after starting the engine.
Before starting the engine, be sure to confirm the
coolant and oil levels according to the Operation
Manual or check them with the instruments. etc.
ii) When turning the track frame, be sure to let two
work crew stand at the front and rear sides of the Track frame
90°
upperstructure and give instructions for gradually
turning the track frame.
Turning
iii) The rear side of the track frame incorporates the Fig. 9
back-and-forth travel pipings and hoses. Hold
iv) Be sure to set the engine speed to low idle
before stopping the engine.
For high-cab machines with the cab removed,
care should be particularly taken. Hold
Under side
(Right & left)
Under side Fig. 10
2 Cleaning and finishing (Right & left)
1 Clean the front and rear & right and left surfaces
(indicated by in Figs.10 and 11) of the track
frame.
2 Check the surfaces for damage or scratches.
Detail E
Note:
If they are damaged repair and/or refinish them. Spot facing
3 Clean all spot facing surfaces of the track frame.
Under side
Fig. 11
59
Step 4
Lift
Connecting the upperstructure to the side frame (left)
Lift
1 1 Move the upperstructure assembly horizontally in
the direction of the arrow .
Note:
Set the travel device side of the side frame assembly
and the Travel Piping and hoses side of the track
frame assembly in the same direction. (See Fig. 12) Side frame
(left)
Travel Device
Fig. 12
2 Moving the upperstructure horizontally in the
direction of the arrow, align the centers of the
Detail F
connecting parts of the side frame and track frame.
Lift & move
Track Side frame

frame (left)
3 Connect the side frame to the track frame.

Fig. 13
Hold
Fig. 14
60
2 1 Align the bolt holes of the side frame and track Hold
frame to be connected and then connect them
together with bolts 08 and spacer 09 .
Notes:
i) Be sure to apply a suitable lubricant to the fixing
bolts 08 before tightening. Use the lubricant
made by mixing a white zinc jelly and spindle oil
in 1:1 proportion.
ii) Apply a lubricant to the under-side of the bolt
head marked with , before insertion as
iii) Place the spacer 09 on the bolts 08 with the
chamfer directed to the bolt head.
iv) Tighten all bolts till the surfaces engage fully.
v) Confirm that there is no space between the
contacted surfaces.
Fig. 15
Detail G
09
Detail H
09 Section a
08 Chamfer 08
Fig. 17
09
Note:
Be sure to similarly treat all the remaining bolts.
2 Tighten the bolts 08 on the front side following the

same procedure as that for those on the rear side.
Fig. 16
Detail I
3 Tighten temporarily using a power wrench.
CAUTION:
Perform this Step avoiding your hand getting caught by
the reaction force bar of the power wrench.
Fig. 18
61
Step 5 Detail J
Hold
Connecting the side frame (right) to the track frame
1 1 Place 2 wooden blocks under the other side of the

track frame as shown in Fig. 20.
Wooden block: 2 pcs.

Size: 800 mm (L) × 1 200 mm (W) × 1 150 mm (H)
Fig. 19
(30 in) (47 in) (45 in)
Note:
The wooden block must be able to carry more than
10 000 kg (22 000 lb) in weight.
CAUTION:
This is safer than lifting the upperstructure by another
crane.
Wooden approx.
2 Turn the upperstructure at 90°. block 1 150 mm
(2 pcs.) (45 in)
2 1 Clean all female screws of the side frame (under
using a tap. (Perform the work in a manner Fig. 20
be-scribed in 3 of Step 1 on the previous page.
Lift
Tap size: M42×3
2 Clean the side frame (right) 07 surfaces to be

connected to the track frame.
Wire ropes
3 Check the surfaces for damage or scratches. Side frame (right) 07 26 mmø ×
8 000 mm
Note:
If they are damaged, repair and/or refinish them.
3 1 Lift the side frame (right) 07 as illustrated in Figs. a

21 and 22.
b
Note:
Fig. 21
Apply protectors at 12 points a , b and c , indicated c
by to prevent the wire ropes from breaking.
Side frame (700G) 07 weight: 15 200 kg (33 510 lb)

Side frame (900G) 07 weight: 15 900 kg (35 053 lb) Hold
Lift & move
Wire ropes used: 2 pcs. at
26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L)
Protectors: 12 pcs.
2 Moving the side frame assembly (right) horizontally

in the direction of the arrow, align the centers of
the connecting parts of the side frame and track
frame.
Side frame
(right) Track frame
Fig. 22
62
4 As explained in "Step 4" apply a lubricant to the fixing
Hold
bolts before installing.
Hold
1 Connect the track frame to side frame.
2 Align the bolt holes of the side frame and track

frame to be connected and then connect them
together with bolts 08 and spacer 09 .
Notes:
bolts 08 before tightening. Use the lubricant made
by mixing a white zinc jelly and spindle oil in 1:1
proportion.
ii) Apply a lubricant to the under-side of the bolt head
marked with , before insertion as illustrated in
Fig. 25.
iii) Place spacers 09 on bolts 08 with the chamfer
directed to the bolt head. Fig. 23
iv) Tighten all bolts till the surfaces engage fully Detail K
v) Confirm that there is no space between the
contacted surfaces.
a 09
Detail L
09 Section a
Chamfer
08
Fig. 25
Fig. 24
Note:
Be sure to similarly treat all the remaining bolts. Detail M
3 Tighten the bolts 08 on the front side following the
same procedure as that for those on the rear side.
4 Tighten temporarily using a power wrench.
CAUTION:
Perform this step avoiding your hand getting caught by
Fig. 26
63
Step 6
Removing the wooden blocks Hold
Hold
Wooden blocks
1 1 Lower the crane. Fig. 27

2 Place hydraulic jacks a (indicated by ) at
the front and rear of the underside beam of the
track frame. Hold
Lower
3 Extend the jacks placed on the front and rear sides
at the same time.
4 Jack up the track frame high enough to remove the
Take off the crane
wooden blocks applied previously. wire ropes
Hydraulic jack: 2 pcs.

for 20 tonne (22 US ton) load
CAUTION:
Keep each block placed under the jack securely.
5 Take of crane (Front side) wire ropes lifting the
side frame.
a
Fig. 28
Take off the crane

wire ropes
2 1 Remove the wooden blocks.

2 Retract 2 hydraulic jacks a (indicated by )
at the same time to ground the track frame.
3 Take off crane (Rear side) wire ropes lifting the
side frame.
Fig. 29
64
Step 7 Lift
The tightening procedures for the bolts used to attach the

track frame are described below
Track link
CAUTION:
Do not loosen valve a quickly or loosen it too much as
high-pressure grease in the adjusting cylinder may gush
out. Loosen carefully, keeping body parts and face
away from valve a . Never loosen grease fitting b .
Detail N
CAUTION Fig. 30
CAUTION: Never touch
While lifting the track link with a crane, place a sleeper b Fitting
between the track link and side frame to avoid
dropping. a Valve
1 1 Loosen the valve a at the track adjuster. Never Grease outlet Fig. 31
touch the fitting b . (Fig. 31)
2 Lift the track link using a crane as illustrated in
Fig. 30.
Wire rope
Note 1: 36 mmø ×
8 000 mm
Apply protectors to parts c , indicated by
Fig. 32. Track link
c
Track link weight: Approx. 10 000 kg (22 000 lb)
c
Wire rope: 1 pc.
36 mmø × 8 000 mm (L)
(1.4 inø) (312 in L) Detail O
Protector: 2 pcs.
Fig. 32
Note 2:
When lifting the track link, grease will come out of
the valve a .
Catch it with the vinyl bag provided. Sleeper
Fig. 33
Notes 3:
Hold
i) Lift the track link to achieve clearance between
the track link and the side frame's upper face as
shown in Fig. 33.
ii) Be careful so as not to break the wire rope.
2 Also fix the remaining bolts on the opposite side frame,

by the same procedure mentioned above.
Loosen the valve a at the track adjuster at the

opposite side again following the same procedure
mentioned above.
Clearance between the track

link and side frame
Fig. 34
65
Hold
Step 8
Retightening the remaining bolts
1 Retighten the right-side bolts.

Tighten these right-side bolts with the specified torque
using a power wrench.
Tightening torque of M42 bolt: 4 000 N·m

(400 kgf·m/2 890 lbf·ft)
Width across flats: 65 mm
Note:
Keep the track link lifted by the crane until the right-
side bolts are tightened completely.
Fig. 35
Detail P
CAUTION:
i) While lifting the track link with a crane. place a
sleeper between the track link and side frame to Power wrench
(4093799)
a void dropping.
ii) Perform this step avoiding your hand getting
caught by the reaction force bar of the power
wrench.
2 Tighten the side bolts fitted temporarily in "Step 4" and

"Step 5" with the specified torque using a power Fig. 36
wrench. Hold

(400 kgf·m/2 890 lbf·ft)
CAUTION:
Perform this step avoiding your hand getting caught by
3 Retighten the bolts located on the left side.
Fig. 37
Detail Q
Power wrench
(4093799)
Fig. 38
66
6-3 Connection of travel motor hoses
Step 1
Connection of the travel motor hoses
1 Remove the wires that are holding the travel motor

hoses in place as shown in Fig. 2.
2 Connect the travel motor hoses c and d as shown in

Fig. 4.
Tightening torque of M10 socket bolt c and d :

500 N·m
(50 kgf·m/369 lbf·ft) Fig. 1
Socket size: 50 mm Detail A
Notes:
i) Clean the surfaces of the travel motor to be
connected to the hoses.
ii) Make sure that there is no dust sticking to the
seat face of each hose.
iii) Be careful not to twist the hoses when
connecting them.
iv) Use O-rings (P/No. 4187329~2) to install the
hoses. Apply a thin layer of sealant #98D to the
O-rings before installation.
Wires
3 Connect the travel motor pilot hoses e and f as Fig. 2

shown in Fig. 4.
Detail B
Tightening torque of hose e : 60 N·m
(6 kgf·m/44 lbf·ft)
Tightening torque of hose f : 120 N·m
Notes:
i) Clean the surfaces of the travel motor to be
connected to the hoses.
ii) Make sure that there is no dust sticking to the
seat face of each hose.
iii) Be careful not to twist the hoses when Fig. 3
connecting them.
Detail C
e
Clamps g
4 Hold the travel motor hoses c , d and pilot hoses e ,
f in place with clamps g .
Connect the hoses on the opposite side of the

travel motor in the same way.
f
5 After the oil has run out, clean the parts carefully.
c
d Fig. 4
67
Step 2
Installation of covers, ladders and steps
1 Install the covers 27 , 28 . Detail D
Note:
Install the mounting bolts, etc. on the opposite side.
Cover 27 (R) weight: 25 kg (55 lb)

Cover 28 (L) weight: 25 kg (55 lb)
Tightening torque of M16 bolt: 210 N·m

27 (R)
28 (L)
Notes:
i) Apply lubricant to the mounting bolts, fit all bolts
Fig. 5
in place, and then tighten them with the specified
torque.
ii) Similarly, make assembly on the opposite side.
30
2 Install the ladders 30 .
Note:
Ladder 30 (For 700 mm shoe) weight: 20 kg (44 lb)

30
Notes:
i) Apply lubricant to the mounting bolts, fit all bolts
in place, and then tighten them with the specified
torque. Fig. 6
ii) Similarly, make assembly on the opposite side.
3 Check that all the tightening bolts of the undercarriage

are securely tightened. Detail E
Fig. 7
68
6-4 Assembly of cab & handrail, step and ladder etc.
OUTLINE
Backhoe-Front
1 Installation mirror, head lamps, antenna, and wiper on the cab.

2 Installation of fenders, steps and ladder, etc.
3 Installation of fender, handrails and step.
4 Installation of duct assembly.
5 Instaration of air cleaner caps and exhaust pipe.
Backhoe-Front
Fig. 1
69
Step 1
Backhoe-front cab assembly

Backhoe-front machines are shipped according to the low-cab specification.
Installation of miscellaneous parts on the cab.
Note:
1 Install the handrail 40 .
2 Mount the mirror 39 and 41 .
3 Install the lamp 42 on the cab and connect the cords.
Fig. 2
4 Install the antenna 43 on the cab and connect the
cords.
5 Mount the wipers 00 on the wiper motors and connect

the cords.
Detail A
42 Lamp 43
Wiper assembly Antenna
00
Wiper assembly
00
Mirror 39
Mirror 41
Handrail 40
Fig. 3
70
Step 2
Mirrors mounting location & angle
1 Cab installation mirrors
Detail B
39
155 mm (6.1')
41
210 mm (8.3')
Fig. 4
Detail C
10° Fig. 5
Detail D
30°
Fig. 6
71
2 Left fender installation mirror
Detail E
625 mm (2'6'')
Fig. 7
Detail F
30°
Fig. 8
Detail G
15°
Fig. 9
72
3 Right fender installation mirrors
Detail H
850 (3')
45° 960 (3'2'')
Fig. 10
Detail I
45°
30° 30°
5°
Fig. 11
Detail J
15°
Fig. 12
73
Step 3
Installation of fenders, step, ladder, etc.
1 Wire ropes required 2 1 Install fenders 37 , 24 , 25 , steps 44 , ladder 27 on the

base machine. To install fender 37 by the side of
Wire rope: 4 pcs. the cab, use bolts.
8 mmø × 5 000 mm (L) 2 Install chain 45 to the cab and fender 37 .
(0.3 inø) (195 in L) 3 Install mirror 38 to the fender 37 .
4 Install handrail 34 on the oil tank in hand rail 35 on
Fender 24 weight: 84 kg (186 lb)
the battery box.
Fender 25 weight: 131 kg (288 lb)
Ladder 27 weight: 462 kg (1 018 lb) Note:
Handrail 34 weight: 15.8 kg (34.8 lb)
Fender 37 weight: 254 kg (559 lb) Tightening torque of M12 bolt: 90 N·m
Mirror 38 weight: 2.49 kg (5.49 lb) (9 kgf·m/66 lbf·ft)
Step 44 weight: 19 kg (42 lb)
Chain 45 weight: 0.4 kg (0.88 lb)
Notes: (27 kgf·m/200 lbf·ft)
i) Apply lubricant to the bolts before installing. Width across flats: 24 mm
ii) After screwing all the bolts by hand,tighten them
to the specified torque.
Detail K
35 34 BEFORE
44
45
38
37
27
25
24 Fig. 13
Detail L
34 AFTER
35
45
44
38
37
27
25
24
Fig. 14
74
Step 4
Installation of fenders, handrails and step, etc.
1 Wire ropes required 2 1 Install fender 49 , step 56 and handrails 59 , 60 , 61 on

the base machine. To install fender 49 by the side
Wire rope: 4 pcs. of the Fuel tank, use bolt.
8 mmø × 5 000 mm (L) 2 Install mirrors 55 , 57 on the handrail a .
(0.3 inø) (195 in L) 3 Install hose-reel 50 , lamp 51 on the fender 49 .
Fender 49 weight: 174 kg (384 lb) Note:

Hose-reel 50 weight: 33.8 kg (74.5 lb) Install the mounting bolts, etc. on the opposite side.
Lamp 51 weight: 1.1 kg (2.4 lb)
Mirror 55 weight: 2.89 kg (6.37 lb) Tightening torque of M10 bolt: 50 N·m
Step 56 weight: 3.58 kg (7.89 lb) (5 kgf·m/37 lbf·ft)
Mirror 57 weight: 1.93 kg (4.3 lb) Width across flats: 17 mm
Handrail 60 weight: 27.7 kg (61 lb) Tightening torque of M12 bolt: 90 N·m
Handrail 61 weight: 7.35 kg (16.2 lb) (9 kgf·m/66 lbf·ft)
Notes:
i) Apply lubricant to the bolts before installing. Tightening torque of M16 bolt: 270 N·m
ii) After screwing all the bolts by hand,tighten them (27 kgf·m/66 lbf·ft)
to the specified torque. Width across flats: 24 mm
Detail M
61 60 BEFORE
59
49
50
57
55 a 51 56 Fig. 15
Detail N
61 60 AFTER
59
49 56
50
57 51
55
Fig. 16
75
Step 5
Installation of duct assembly
1 Wire ropes required 2 Install the duct assembly 14 , 15 using bolts 16 bolt sems
17 on the basic machine.
Wire rope: 4 pcs.

8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L) (14 kgf·m/103 lbf·ft)
Duct assembly 14 weight: 75.6 kg (166.7 lb)
Duct assembly 20 weight: 75.4 kg (166.2 lb) Notes:
i) Apply lubricant to the bolts before installing.
Note: ii) After screwing all the bolts by hand,tighten them
Stated here is the assembly procedure for the low- to the specified torque.
cab-use upper structure. The same procedure will be
applied for the high-cab-use upper structure.
Detail O
BEFORE
16
Duct assembly hinge
mounting sems bolt -4
17
Duct mounting bolt, 16

assembly -8
16
Duct assembly hinge 17

mounting sems bolt -4
16
Fig. 17
Detail P
AFTER
14
15
Fig. 18
76
Step 6
Removal of a SCR muffler

a
Removal of a SCR muffler
1 Remove cover a on the engine.
2 Remove the V-clamp b with which an engine and

a muffler pipe are being connected.
Cover a weight: 6.08kg (13.4 lb)

Fig. 19
Detail Q
3 Remove a muffler jig mounting bolts c .
Bolt c weight: 7.1 kg × 6

(16 lb)
CAUTION:
When reducing a bolt, please be careful so that a finger
isn't picked up.
4 Attach wire ropes and shackles to the hooks on

V-Clamp b
SCR muffler jig.
Fig. 20
And lift them by a crane, and put it in the flat place.
SCR Muffler jig d weight: 1 116 kg (2 491 lb)
Wire rope: 2 pcs.

10 mmø × 5 000 mm (L) : 2 pc.
(0.4 inø) (197 in L)
Shackle: 4 pc.
for 0.5 tonne (0.55 US ton) load
Bolt c
Fig. 21
Detail R
d
Fig. 23 Fig. 22
77
78
6-5 Installation of counterweight, SCR muffler, camera and rear lamps
Detail A
To install the counterweight, follow the installation
Hold
procedure for the low-cab-use upper structure stated
below.
Wire ropes
26 mmø ×
Step 1 8 000 mm
Wire ropes
Installation of the counterweight 26 mmø ×
Shackle 8 000 mm
1 1 Attach the wire rope with a shackle to

Detail B
the eye plate provided on
counterweight 02 as shown in Fig. 1. Wire rope
02
2 Lift counterweight 02 as shown in

Shackle Hold
Figs. 1, 2 and 3. Eye
plate Eye plate
Counterweight 02 weight: 18 000 kg
(39 682 lb) Fig. 2 Fig. 1
Wire rope: 2 pcs.

26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L)
Shackle: 2 pcs.
10 tonne (11.0 US ton) load
02
Counterweight Fig. 3
Lift & move
2 1 Lift the counterweight horizontally as illustrated in

Fig. 4.
CAUTION:
Never allow anybody to stand directly beneath the lifted
counterweight.
Beam
2 Move the counterweight onto the rear beam as
shown. Fig. 4
Hold
3 Set the counterweight on the rear beam.
Fig. 5
79
4 1 Set the counterweight 02 with 10 bolts 03 and 10
washers 04 .
Notes:
bolts before tightening. Use the lubricant made Hold
by mixing a white zinc jelly and spindle oil in 1:1
proportion.
Bolt 03 weight: 6.24 kg (13.8 lb)

Washer 04 weight: 0.88 kg (1.9 lb)
ii) Apply a lubricant to the under-side of the bolt

head marked with , before insertion as
iii) Tighten all bolts till the surfaces engage fully.
iv) Confirm that there is no space between the
contacted surfaces.
v) Assemble washer 04 in such way so that the
"darin hole" faces dowanward. Fig. 6
Detail C
02 04
03
Fig. 7
2 Tighten the counterweight with 10 bolts 03 .
02
Note:
Tighten with a power wrench as shown in Fig. 8.

(400 kgf·m/2 950 lbf·ft)
CAUTION: 04
Be sure to avoid your hand getting caught by the
reaction force bar of the power wrench. 03 Fig. 8
Drain hole
5 Take off the crane wire ropes lifting the counterweight.
Fig. 8-a
80
Step 2
Install drain off hose
1 Install drain off hose to counterweight Detail D
Tube, plastic 96 weight: 0.03 kg (0.07 lb) 96

Pipe 97 weight: 0.28 kg (0.63 lb)
Tube, plastic 98 weight: 0.03 kg (0.07 lb)
Clamp, hose 99 weight: 0.01 kg (0.02 lb)
Clip 100 weight: 0.01 kg 0.02 lb)
Clip, hose 101 weight: 0.01 kg (0.02 lb) 102 100
Bolt, sems 102 weight: 0.03 kg (0.07lb)
Tightening torque of M10 bolt: 50 N·m 99

(5 kgf·m/36.8 lbf·ft)
101
Tightening torque of clamp hose: 6 N·m 102
(0.6 kgf·m/4.42 lbf·ft) Fig. 9
Notes: Detail E
i) Please be careful to one of camp.
ii) Please get the sense of the clamp like Fig 10
101
and 11.
102
97
102
101
99
98
Fig. 10
Detail F
Fig. 11
81
Step 3 Detail G
Lift
Installation of exhaust pipe
1 Install SCR muffler assembly
1 Attach wire ropes and shackles to SCR muffler

assembly A as shown in Fig. 12. Wire rope
10 mmø × 5 000 mm
2 Install SCR muffler assembly to counterweight.
A
(Fig. 13)
Shackle
SCR muffler assembly A weight: 289 kg (637 lb)
Wire rope: 2 pcs.

10 mmø × 5 000 mm (L) : 2 pc.
Fig. 12
(0.4 inø) (197 in L)
Shackle: 4 pc.
A

Fig. 13
Detail H
Note: SCR muffler assembly
Install the exhaust pipe of the muffler on the
machine with the exhaust port backward.
3 Install SCR muffler assembly and pipe a in
V-clamp b .(Fig. 15)
Notes:
i) Apply lubricant to the bolts before installing.
ii) After screwing all the bolts by hand,tighten them
to the specified torque.
Bolt Washer Fig. 14
Detail I
pipe a V-Clamp b
Bolt c
J281230 (Reuse bolt) Fig. 15
Fig. 16
82
2 Install exhaust plumbing fixed bracket Detail J
1 Install exhaust plumbing fixed bracket to

counterweight. (Fig. 17)
2 Install U-bolt 95 to exhaust plumbing fixed bracket.
(Fig. 17)
95
Muffler bracket assembly 93 weight: 11.1 kg (24.4 lb)
U-Bolt assembly 95 weight: 0.82 kg (1.81lb)
Tightening torque of M12 bolt, Nut: 90 N·m

Width across flats: 19 mm 93 94
Fig. 17
3 Maintain pipe 105 under the muffler, and tie hose 103
to pipe 107 . Detail K
Hose 103 weight: 0.22 kg (0.49 lb)

Clamp, hose 104 weight: 0.01 kg (0.02 lb)
Pipe 105 weight: 3.67 kg (8.09 lb)
Pipe 107 weight: 0.54 kg (1.20lb Clamp
Tightening torque of clamp hose: 6 N·m

(0.6 kgf·m/4.42 lbf·ft)
Width across flats: 7 mm 107 103 105
104 104 104
Shackle: 4 pc.
Fig. 18
Note:
Please don't tighten a hose clamp too much. Detail L
There is a fear that a hose clamp is destroyed.
4 Install pipe assembly 106 to pipe 105 .
Pipe assembly 106 weight: 0.95 kg (2.1 lb)

(2.0 kgf·m/14.7 lbf·ft)
5 Install exhaust assembly 92 to SCR muffler.
Exhaust assembly 92 weight: 46.6 kg (103 lb)

Gasket 91 weight: 0.01 kg (0.02 lb) Clamp
106 Fig. 19

Note:
91
The gasket attach a new article by all means.
94
Bolt c
Fig. 20
83
3 Installation of the clamp hose Detail M
1 Insert tube plastic in exhaust lower pipe and attach

it in clamp hose 99 .
99
Hose, clamp 99 weight: 0.01 kg (0.02 lb)
Tightening torque of clamp hose: 6 N·m

(0.6 kgf·m/4.42 lbf·ft)
4 Installation of exhaust pipe Fig. 21
1 Install ejector 89 to exhaust assembly 92 .

Detail N
Ejector 89 weight: 15.0 kg (33 lb)
Gasket 90 weight: 1.20 kg (2.65lb)
Tightening torque of M12 bolt, Nut: 90 N·m

89
Note:
The gasket attach a new article by all means. 90
Fig. 22
5 Install an urea hose in SCR muffler
1 Install cover 109 to a muffler bracket.

Detail O
2 Fix urea hose to the muffler bracket in clamp hose.
3 Install an urea hose in SCR muffler.

125 109
132
Cover 109 weight: 3.01 kg (6.77 lb)
J271025 131
Bolt, sems 125 weight: 0.04 kg (0.02 lb)
Bracket 130 weight: 0.15 kg (0.33 lb)
Clip 131 weight: 0.038 kg (0.08lb)
Bolt, sems 132 weight: 0.03 kg (0.07lb)

(5 kgf·m/36.8 lbf·ft) YA00049222 Clip 130
132 Fig. 23
Notes: Detail O-a

i) When stopping the urea hose in the clamp,
Connector
please be careful not to cross.
ii) Insert the connector of the urea hose until it
clicks.
Fig. 24
84
6 Install a wiring to SCR muffler Detail P
1 Fix the harness with the clip and clip band as

J271040 Bolt
shown in Fig. 25. 4269658 Spacer YA00049110
YA00049118 Clip
2 Attach the wiring couplers a , b , c to the SCR
muffler as shown in Fig. 26.
Note:
J271025 Bolt
After installing the wiring coupler, wire and coupler in
4622454 Clip band
tie wrap Please fix.
YA00049222 Clip
Fig. 25
Detail P-a
a
b
Fig. 26
85
7 Installation of the SCR muffler covers Detail Q

Bracket 119 weight: 1.33 kg (2.93 lb) Fig. 27
Bracket 122 weight: 0.03 kg (0.07 lb) Detail R
Bolt, sems 123 weight: 0.04 kg (0.09 lb) 113
125
Bolt, sems 124 weight: 0.04 kg (0.09 lb) 125
111
Width across flats: 17 mm 123
124
118 119 124 123

Fig. 28
Detail S
125 119
119
123
112 122
121
120
123
124
Fig. 29
Detail T
125
125 125
125
117 111 111 116
Fig. 30
86
Step 4
Installation of the camera ass'y and rear lamp ass'y
1 Install the camera 65 on the counterweight
1 Install camera 65 .
Note:
Camera 65 weight: 2.3 kg (5.1 lb)

2 Connect electric wire coupler a .

Note:
Notes: Stated here is the assembly procedure for the low-
i) Before connecting the electric wires, remove the cab-use upper structure. The same procedure will be
anti-corrosive and any rust from the couplers. applied for the high-cab-use upper structure.
ii) Connect the couplers on the labels.
2 Install the rear lights 68 on the counterweight
1 Install rear lights 68 .
Note:
Lamp 67 weight: 0.5 kg (1.1 lb) × 2

Bracket 68 weight: 0.22 kg (0.49 lb) × 2
Bracket 69 weight: 1 kg (2.2 lb) 68 × 2

Width across flats: 19 mm Fig. 31
2 Connect electric wire coupler b and c .
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
Detail U
a c
69
c
67
68
65
69
68
67
Fig. 32
87
Step 5
Installation of the aerial angle camera (1)
1 Install the aerial angle camera 00 on the counterweight
1 Install aerial angle camera 00 .
Note:
Aerial angle camera 00 weight: 0.29kg (0 .64 lb)

Spacer 34 weight: 0.03 kg (0.07 lb)
Rubber, cushion 36 weight: 0.02 kg (0.04 lb)
Washer 06 weight: 0.02 kg (0.04 lb) Note:
Nut 07 weight: 0.01 kg (0.02 lb) Stated here is the assembly procedure for the low-
Bolt, sems 24 weight: 0.03 kg (0.07 lb) cab-use upper structure. The same procedure will be
applied for the high-cab-use upper structure.

(9kgf·m/66 lbf·ft)
2 Connect electric wire couplers a and a' .
Notes:
Fig. 33
Detail V
26
24
11
a' a
00 01
35
07
06 36 34 39 02
Fig. 34
88
Step 6
1 Install the aerial angle camera 00 on the ladder side

handrail
Aerial angle camera 00 weight: 0.29 kg (0 .64 lb)

Nut 07 weight: 0.01 kg (0.02 lb)
Bolt, sems 14 weight: 0.44 kg (0.97 lb) Note:
Clamp, pipe 27 weight: 0.07 kg (0.15 lb) Stated here is the assembly procedure for the low-
Clamp, pipe 29 weight: 0.07 kg (0.15 lb
cab-use upper structure. The same procedure will be
Tightening torque of M10 bolt: 50 N·m applied for the high-cab-use upper structure.
2 Connect electric wire coupler a .
Notes:
Fig. 35
Detail W
a 34 36 06 07
01
35 29
14
00 02 39 34 36 06
10
27 13
Fig. 36
89
Step 7
1 Install the aerial angle camera 00 on the left side step

front side handrail

Clamp, pipe 14 weight: 0.44 kg (0.97 lb) cab-use upper structure. The same procedure will be
Bolt, sems 27 weight: 0.07 kg (0.15 lb) applied for the high-cab-use upper structure.

Notes:
Fig. 37
Detail X
36 34
39 02 01
07
14 35
29
a' 06 a 00
11
13
27 Fig. 38
90
Step 8
1 Install the aerial angle camera 00 on the right fender

anterioris handrail

Clamp, pipe 14 weight: 0.44 kg (0.97 lb) cab-use upper structure. The same procedure will be
Bolt, sems 27 weight: 0.07 kg (0.15 lb) applied for the high-cab-use upper structure.

Notes:
Fig. 39
Detail Y
01 02 39 34
07 a'
35 29
14
a
00 36 06
08
13
27
Fig. 40
91
Step 9
Note:
Bundle up the harness which remained under the
right fender.

Note:
The installation angle of the camera is reference in
Servic Bulletin.
Fig. 41
Detail Z
23 J271025
48 YA00049125
Fig. 42
92
Check that all the tightening bolts of the superstructure
are securely tightened.
Detail A
Fig. 43
93
94
6-6 Greasing of swing bearing
Greasing (1) Detail A
1 The machine is provided with a electrically operated

grease lubricator connected to the hose reel and a a
grease gun.
Manual
Operation procedure:
1 Move lubrication control valve lever a in the Auto

lubricator box to the MANUAL position.
2 Turn lubrication mode switch b on the switch

panel under the left armrest to the MANUAL
Fig. 1
position.
Auto-lubrication alarm on the monitor panel comes
ON at this time. Detail B
Note:
A lit auto-lubrication alarm does not mean that the
auto-lubrication system has become inoperable.
b
This is a normal operation at this time.
3 Using the lubricator and grease gun, add grease to

the respective greasing points.
IMPORTANT:
Fig. 2
In order to prevent damage to the pump, please follow
the procedure after manual lubrication ends.
4 Turn OFF the automatic grease changeover switch

b .
5 Pull out the grease gun and remove the residual

pressure inside the hose of the pump unit and
hose reel.
A small amount of grease with residual pressure is Fig. 2-1
discharged.
95
2 Start the engine.
3 Supply grease to 4 points as shown in Fig. 4.
Notes:
i) When using a lubricator, increase the engine
speed above medium speed.
ii) If an optional automatic greasing system is not
equipped, the EX1200-7B comes equipped with a
standard air grease gun. Grease up at the front
pins with the air grease gun manually.
iii) Insufficient greasing will cause wear to the pins.
Fig. 3
Detail C
Swing bearing
Fig. 4
96
4 Lubrication mouthed
(1) Turn power switch ON to activate the pump.

Grease is sucked up and supplied to high-pressure
grease gun a .
IMPORTANT:
When the pump begins to suck grease, any air inside
pump will be mixed in, making grease turn whitish.
Open check valve cock to bleed this air-mixed grease.
Securely close check valve cock when all air-mixed
grease is bled out. b
a
(2) Grab high-pressure grease gun a and pay out the
hose from hose reel b to the length required.
(3) Press hydro-chuck d protruding from high-

d
pressure grease gun a into a grease nipple and
c
pull the lever to discharge grease.
a
(4) Release the lever when greasing is complete

grease discharge will stop.
Fig. 5
IMPORTANT:
When detaching hydro-chuck d from grease nipple e ,
grease nipple e tip may break unless a special care, is
taken, as follows: d
• Tip nozzle c a little so as to release the connecting
pressure applied to hydro-chuck d .
• Slowly detach hydro-chuck d from nipple e .
(5) When all greasing work is complete, turn power

switch OFF, then pull grease gun a lever to
release remaining pressure from grease gun a ,
pump, and the hose so as to ensure long life of the e
components. A little grease will be discharged at Fig. 6
this time.
Note:
The hose has a limited service life. Periodically
inspect the hose for cracks, grease leakage, or any
other damage. If any damage is found, replace the
hose.
97
98
6-7 Vacuuming (air purge work) & charging of refrigerant
If the amount of refrigerant is insufficient, the cooling capacity

will decrease.
Please inject the default amount of refrigerant quantity.
CAUTION:
DO NOT allow liquid refrigerant to contact eye or skin.
Liquid refrigerant will freeze eye or skin on contact be
careful not to loosen connections in the air conditioning
circuit.
IMPORTANT:
When filling the air conditioner with refrigerant, set the
key switch, located on the right control box in the cab,
to the ACC position turn on the main air conditioner
A/C switch on the right control box turn on the auxiliary
cooler fan switch and perform vacuuming of the circuit
through both the SUC and DEC ports of the
compressor.
Engine is ON as described in operation manual.
But do not get the engine started up.
99
Necessity of Vacuuming (Air Purge)
The following damage will be generated if the air or

other gases remain in the refrigeration cycle, so
discharge the air completely from the refrigeration
cycle, and then charge the refrigerant (R-12 or R134a).
(1) High Pressure Rise

Air
If the air remains in the refrigeration cycle, the heat
exchange between the refrigerant and the cooled
air in the condenser will be very poor, and will
cause pressure rise on the high pressure side.
Since the liquified temperature of the air is very low,
even if the gas refrigerant is liquified, it will not be
liquefied, keeping gas phase in the condenser.
In other words, the effective heating area to liquify
the gas refrigerant in the condenser will become
smaller which corresponds to the volume of the
remaining air, and cause pressure rise on the high
If air remains in the refrigeration cycle,
pressure side. it will cause high pressure rise.
Fig. 1
(2) Metallic Corrosion

If the air remains in the refrigerant cycle, it will
cause chemical reaction between the moisture in
the air and the refrigerant, and generate
hydrochloric acid, which will corrode the metals
used in the cooler such as aluminum, copper, and
iron. Therefore, it is necessary to completely extract
the moisture from the refrigeration cycle.
If there is moisture, Hydrochloric acid

hydrochloric acid
will corrode metals. Corrode metal
Fig. 2
(3) Moisture Clogged in Expansion Valve

If there is moisture in the refrigeration cycle, the
high-pressure refrigerant will be throttled by the
expansion valve, and when the refrigerant pressure
drops, the moisture contained in the refrigerant will
freeze at the orifice of the expansion valve and clog
up the refrigerant flow. For this reason, the
refrigeration cycle becomes unstable, and will Frozen
reduce the cooling capacity substantially.
Ice clogged in expansion valve Clog up refrigerant flow

will clog up refrigerant flow
and reduce cooling ability. Reduce cooling ability
Fig. 3
100
SUBJECT
MAINTENANCE OF MACHINES EQUIPPED WITH AN AIR CONDITIONER

CHARGED WITH 134a REFRIGERANT
OUTLINE
In order to prevent an atmospheric ozone layer from being harmed, we have completely shifted our production
from air conditioners using R12 refrigerant gas to those using R134a refrigerant gas. This procedures describes
how to handle the new refrigerant, R134a. A new compressor oil is also specified for each model, and care
should be directed to the compressor oil.
Compressor oil
The new R134a refrigerant gas is incompatible with the R12 conventional refrigerant gas. Compressor oil
dedicated to each model is specified on the next page.
Shipping
As production has been shifted to the new air conditioners, EX1200-7B machines will be shipped with
refrigerant gas charged at the factory. Thus, charging of refrigerant gas for delivery is no longer required.
Refer. to the following page for servicing precautions, etc.
PRECAUTIONS
The new R134a refrigerant gas is incompatible with conventional R12 refrigerant gas.
A new compressor oil is specified for each model.
Model Serial No. Type of refrigerant gas / amount Type of compressor oil / amount
Refrigerant gas: R134a Compressor oil: ND-OIL 8

EX1200- 7B S/No. 07001 ~
Amount: 1,250 g Amount: 40 cc
Charging incorrect refrigerant gas or compressor oil will cause the air conditioner to be damaged very quickly.
101
SERVICE TOOLS
To perform maintenance of the air conditioner using R134a refrigerant gas on EX1200-7B machine, the following tools,
refrigerant, and compressor oil are required.
(These service tools are exclusively used for air conditioners with R134a refrigerant gas and are not compatible with
those for R12 refrigerant gas.)
Tools (R134a refrigerant gas charging tool kit)

P/No. 4360564 (Nihon Denso No. 95048-0061)
Fig. 1
Pump (for evacuation)

Fig. 2
Adaptor (for connecting the evacuation pump)

Fig. 3
Tester (refrigerant leak detector)

Fig. 4
Gas (R134a refrigerant gas - 300 g)

Oil (ND-OIL8, R134a compressor oil - 40 cc)
Oil (ND-OIL8, R134a compressor oil - 1 set)
102
1 CHARGING REFRIGERANT GAS (R134a) AND PREPARATION
For EX1200-7B machine, both refrigerant gas and the oil compressor are charged in the air conditioners before
shipment. Thus, recharging them is not required during delivery.
The explanations given below deal with spontaneous refrigerant gas leaks caused by long-term storage at the place of
shipment, and how to perform service after operation. (The new gas is charged in the same way as conventional R12
refrigerant gases. However, the service tools, charging pressures, etc., differ for each gas.)
1.1 When refrigerant gas has been completely released

If the refrigerant gas has been completely released from a burst in the refrigerant hose, perform the following procedure:
1 Supplying compressor oil

Check for compressor oil leakage (from the hose cap, damaged hose, etc.) and supply oil as required. (Make sure to
use the specified oil.)
Oil should be added into the compressor from the suction port by disconnecting the refrigerant hose from the
compressor suction side (on which "S" is stamped).
2 If a damaged hose has to be replaced, spray compressor oil on the O-ring at the hose cap to prevent it from being
damaged.
3 Replace the condenser (P/No. YA00003889 ) because the desiccating agent inside will have degraded.
4 Perform evacuation.
Note:
The compressor shown in the connection diagram for the charging hose and service valves is different from the used
one on the actual machine connection. See next page for photos of the actual connection.
Evacuation
Why evacuation is required
The greatest attention should be paid to the presence of water in the unit when handling the air conditioner. Since
R134a refrigerant for air conditioners is insoluble in water, even a little water remaining in the unit may freeze in the
expansion valve during operation or cause the compressor valve to rust. Thus, it is required that any residual water in
the unit be removed as much as possible before charging refrigerant. The only way to minimize the water in the unit is to
boil it by evacuation and remove it in gas phase. A vacuum pump can be used to drain the water in the unit in a
relatively short time, by maintaining a vacuum.
Evacuation instructions
Check for gas temperature.
Charge refrigerant.
Check for air tightness.
Check for gas leaks.
Performance test.
Start evacuation.
Stop evacuation.
Charge gas.
Approx. 10 min. Allow to stand Correct gauge

More than for 5 min. readings
755 mm
Abnormal
gauge readings Charge refrigerant in gas phase
Tighten piping. at a gauge pressure of 1 kg/cm2
(0.098MPa)
103
Service valve location (machines equipped with air conditioner using R134a refrigerant gas)
EX1200-7B Service valve location

High-pressure side service valve ............. on the upper part (cap on which "H" is embossed)
of the receiver tank
Low-pressure side service valve.............. near the compressor (cap on which "L" is embossed)
High-pressure H
side service valve
Low-pressure L
side service valve
Fig. 5
104
EVACUATION PROCEDURE
1 Gauge manifold connection

1 Close the high-pressure valve (HI) and low-
pressure valve (LO) on the gauge manifold.
2 Connect the charging hoses (red, blue) to the
compressor service valve.
red hose.......... to the high pressure side
(marked D)
blue hose........ to the low pressure side
(marked S)
[NOTE]
The L-shaped end of the charging hose should be
connected to the compressor service valve.
Be careful when doing this because a reversed hose
connection will cause the compressor worm valve to
not open. Fig. 6
Also, take care not to confuse the high and low
pressure sides. Gauge manifold connection
3 Connect the charging hose (green) at the center

of the gauge manifold to the vacuum pump.
2 Evacuation
1 Open the high pressure valve (HI) and low
pressure valve (LO) on the gauge manifold.
2 Turn the vacuum pump switch on and perform
evacuation for about 10 minutes.
3 When the negative pressure scale on the low-
pressure gauge registers 755 mmHg or greater
(= speed at which a vacuum can be obtained),
turn the switch off and close the high pressure
valve and low pressure valve on the gauge
manifold.
Fig. 7
Evacuation
105
3 Airtightness check
1 Close the high and low pressure valves on the
gauge manifold and let stand for more than 5
minutes, then verify that the gauge pointer does
not indicate zero.
2 If the gauge pointer moves toward zero, air is
probably leaking from some location. Tighten the
pipe connections and evacuate again to check for
leaks.
4 Checking for gas leaks

1 Reconnect the charging hose (green), connected
to the vacuum pump, to the service can.
2 Open the service can valve with the charging hose
Fig. 8
(green) gauge manifold nut loosened, and purge
the charging hose with refrigerant pressure Air purge from the charging hose
(retighten the hose when the refrigerant comes
out with a hiss).
3 Open the gauge manifold high pressure valve and

charge refrigerant until the low-pressure gauge
reads 1 kg/cm2. After completing the charge, close
the high pressure valve.
4 Use the leak detector to carefully check for gas
leaks in the cycle.
5 Correct any leaking areas by tightening
connections.
Note:
Gas leaks should be checked only after verifying
that there are no fuel leaks or inflammables present,
to prevent any explosion or fire.
If refrigerant touches an open fire, poisonous gas
(phosgene) will be produced.
Fig. 9
Charging refrigerant used to check for gas leaks
106
5 Charging refrigerant gas.
Charge refrigerant gas from the high pressure side service valve first (Note: Make sure to stop the engine during
this work), then charge from the low pressure side service valve (Note: Do this while rotating the engine and
operating the air conditioner).
The high pressure side service valves are located on the compressor on the receiver tank
for EX1200-7B machine. You can find the valve by removing the cap embossed with an H.
The low pressure service valves for EX1200-7B machine are located on the compressor.
You can find the valve by removing the cap embossed with an L.
Note:
The connection diagram compressor shown for the charging hose and service valve is different from the actual
one used. Refer to the instructions given on page 104.
CHARGING REFRIGERANT
After completing the gas leak check, charge refrigerant gas for the freezing cycle according to the following procedure:
1 Charging from the high pressure side

1
Stop the engine, open the gauge manifold high
pressure valve and service can valve, then charge
refrigerant using approximately 2 service cans
(about 600 g).
EX1200-7B....... approx. 1 000 ~ 1 200 g
CAUTION:
1) Never operate the compressor when charging.
Operating the compressor during this work is very
dangerous, since it causes the refrigerant to flow in
reverse, bursting the service can or hose.
2) Never operate the compressor without charging
refrigerant. This can cause seizing.
3) Do not open the gauge manifold low pressure
valve (this can result in liquid compression).
2 Close the gauge manifold high pressure valve and

service can valve.
Fig. 10
Charging refrigerant (engine stopped)
107
2 Charging from the low pressure side
(additional charging)
1 Verify that the gauge manifold high pressure valve
is closed.
2 Start the engine and open all vehicle doors.
Turn the air conditioner switch on.
3 Set the temperature control lever to "Coldest" and
the blower switch to "HI".
4 Set the engine to run at low idle.
5 Open the gauge manifold low pressure valve and
service can valve, then charge refrigerant until air
bubbles disappear from the receiver sight glass.
6 After charging the refrigerant, close the gauge
manifold low pressure valve and service can
valve, then stop the engine.
7 Carefully check for gas leaks with the gas leak
Fig. 11
detector.
Charging refrigerant (engine driven)
<REFERENCE> Gauge manifold readings

High pressure side................ 14 ~ 16 kg/cm2
(at an ambient
temperature of 30°C)
Low pressure side................ 1.5 ~ 2.5 kg/cm2
(at an ambient
temperature of 30°C)
CAUTION:
1) Never open the gauge manifold high pressure valve (HI). Opening the valve is very dangerous, since it
causes the high pressure gas to flow in reverse, bursting the service can or charging hose (the operator may
be seriously injured).
2) Never turn the service can upside down when charging refrigerant while the engine is running. This causes
the liquid refrigerant to be absorbed into the compressor, resulting in liquid compression. As a result, then the
compressor valve or packing may be broken.
Set the service can upright and charge refrigerant in the gas phase.
At low ambient temperature.

When the ambient temperature is too low to successfully complete charging, put the service can in water
warmed up to 40°C until the refrigerant pressure in the service can increases.
Notes:
Never heat the service can with boiling water or a direct flame.
This can cause it to burst. Always use warm water at 40°C or less.
108
SERVICE-CAN REPLACEMENT
When the service can becomes empty during charging,

replace it with a new one according to the following
procedure:
1 Close the high pressure valve and low pressure
valve on the gauge manifold.
2 Raise the service can valve needle and disc.
3 Install the service can valve on the new service
can.
4 Purge the air from the charging hose as follows:
1) Tighten the service-can valve once, then

loosen it slightly.
2) Slightly open the gauge manifold low pressure
valve.
3) When the refrigerant comes out from the
clearance between the service can and
service-can valve with a hiss, immediately
close the service can valve and gauge manifold Fig. 12
low pressure valve.
Air in the charging hose
Removing the gauge manifold

After complete charging, disconnect the charging hose
from the compressor as follows:
1 Press the L-shaped metal connector on the low
pressure side charging hose (blue) to the
compressor service valve so that the refrigerant
does not leak, then immediately disconnect the
charging hose from the service valve.
2 Immediately after the flare nut is removed,
disconnect the charging hose from the service
valve.
3 Let the hose stand until the high pressure gauge
shows as low a value as possible (10 kg/cm2 or
less).
4 Disconnect the high pressure side charging hose
(red) using the same method as for the low
pressure side.
5 Screw the service can valve handle into the can to Fig. 13
open a hole and continue charging.
Removing the charging hoses
Notes:
1) This work should be done as swiftly as possible to minimize refrigerant leaks. In particular, prompt
replacement is required for the high pressure side after the gauge reads a sufficiently low value, since the
compressor oil as well as refrigerant can rush out (always use a waste cloth).
2) Special care should be taken so that no refrigerant touches the skin or enters the eyes (use safety goggles).
109
Quantity of refrigerant to be charged
When refrigerant is completely released

EX1200-7B .......... 1 250 g (Use five refrigerant gas cans, P/No. 4454005 (250 g) × 5 pcs.
110
1.2 If the quantity of refrigerant gas is insufficient
If the air conditioner does not work properly because of the quantity of refrigerant gas is insufficient, add refrigerant gas
according to the following procedure:
1 Use the tester (leak detector) to check for refrigerant gas leaks.
If any leakage is found at a cap, tighten it. If parts at the leaking location have to be replaced, perform maintenance
according to procedure 1-1.
When a large quantity of refrigerant gas leaks but the tester (leak detector) identifies the leaking portion with
difficulties, find out it while adding refrigerant gas (don't add refrigerant gas more than instructed ! For
quantity to be charged, see page 101.)
2 Charge refrigerant gas from the low pressure side charging port (while starting the engine and operating the air
conditioner). (See the instructions on pages 105 and 110)
Quantity of refrigerant to be charged
When the quantity of refrigerant is low.

Watch the sight glass (liquid eye) at the upper part of the receiver tank during charging.
111
1.3 Troubleshooting
The following are trouble shooting methods when using the R134a refrigerant gas charging tool kit, P/No. 4360564.
<Troubleshooting using the gauge manifold>
1 Normal
<CONDITION>
※ After warming up the engine, examine the

system under the following conditions:
Door: Fully open
Inside air or outside air: inside air
Engine rpm: Low idle
A/C suction port temperature: 30 ~ 35°C
Blower speed: HI
Temperature control: Coldest
<Normal gauge pressure reading>

0.15 ~ 0.25 MPa
Low pressure side
(1.5 ~ 2.5 kg/cm2)
Fig. 14 1.37 ~ 1.57 MPa
High pressure side
(14 ~ 16 kg/cm2)
2 Insufficient refrigerant gases

Phenomenon Cause Points to check
and correct
① Both the low pressure The amount ▼ Check and repair the
and high pressure side of refrigerant gas leak area.
gauges read low is small. Gas
values. leaks. ▼ Add refrigerant.
② Air bubbles ▼ If the gauge reads

continuously pass almost zero, check and
through the sight glass. repair leak area, then
evacuate.
③ The air blown out is
not cold.
Fig. 15
112
3 Refrigerant dose not circulate (clogged cycle)
and correct
① If the cycle becomes Clogged A/C ▼ Check the receiver,
completely clogged, cycle expansion valve, etc.
the low pressure side
gauge immediately ▽ A temperature
reads a negative difference is made
pressure. between the defective
IN and OUT ports.
② If the cycle tends to
get clogged, the low ▼ Make sure to evacuate
pressure side gauge after completing the
gradually begins to work.
show a negative
pressure.
Fig. 16
4 Water contamination in the cycle

and correct
① The A/C performs Expansion ▼ Check the expansion
properly at first, but valve is valve, etc.
after a while, the low frozen due to
pressure side gauge water con- ▼ Replace the receiver
reads a negative tamination. (or dryer).
pressure.
▼ Make sure to evacuate
after completing the
work.
Fig. 17
5 Poor compression in the compressor

and correct
① The low pressure side Damaged ▼ Check the compressor.
gauge reads a high compressor
value, while the high ▽ Poor compression of
pressure side gauge the compressor
reads a low value. <The compressor
body is not hot to
② Both sides read the the touch.>
same value
immediately after
turning off the A/C.
Fig. 18
113
6 Too much refrigerant/poor air cooling in condenser
and correct
① Both the low pressure Too much ▼ Check for amount of
and high pressure side refrigerant refrigerant.
gauges read high
values. Poor air ▼ Correct the refrigerant
cooling in the amount.
② No air bubbles can be condenser
seen in the sight glass ▼ Check and repair the
when decreasing the condenser fin.
engine speed.
▼ Check the vehicle
③ Poor air cooling. cooling system (electric
fan, fluid coupling,
radiator), etc.
Fig. 19
7 Air contamination in the A/C cycle

and correct
① Both the low pressure Air con- ▼ Replace the refrigerant.
side and high pressure tamination
side gauges read high ▼ Make sure to evacuate
values. after completing the
work.
② The low pressure
piping is not cold to
the touch.
③ Air bubbles pass

through the sight glass.
Fig. 20
8 Excessively opened expansion valve

and correct
① Both the low pressure Defective ▼ Check the expansion
side and high pressure expansion valve.
side gauges read high valve
values. ▼ Check the temperature
sensing sleeve
② The low pressure side arrangement.
piping is covered with
frost (condensation). ▽ This phenomenon
often occurs after
replacing the
expansion valve.
Fig. 21
114
Troubleshooting list: Poor air cooling
Air contamination
High-pressure side
pressure is too high Excessively charged refrigerant
Condenser covered with dust
Insufficient refrigerant
Damaged compressor
Normal High-pressure side discharge valve
pressure pressure is too low
Broken gasket (compressor)
Abnormal low pressure pipe
Normal air Normal (crushed, clogged)
volume pressure
Expansion valve open too much
Abnormal Low-pressure side Bad contact of temperature
pressure pressure is to high sensing sleeve
Excessively charged refrigerant
Insufficient refrigerant
Bad contact of temperature
sensing sleeve
Low-pressure side Frosted evaporator
pressure is to low
Abnormal low-pressure piping
Clogged expansion valve
Both high-pressure and

low-pressure side Excessively charged refrigerant
pressures are high
Both high-pressure and
low-pressure side Insufficient refrigerant
pressures are low
Poor air Battery voltage decreases

cooling
Inside of compressor Rotor touches stator
is abnormal
Broken wiring and out-of-place connections
Abnormal
compressor Magnetic clutch Poorly adjusted or defective relays, etc.
Rare short coil
Belt slips Bad ground
Broken coil
Outside air enters form
ventilator and window
Other Temperature control malfunction
Heater is ON
Defective switch
Obstacle around the suction port
Defective resister
Normal blower Frosted evaporator
and motor Battery voltage decreases
Filter plugging
Fusion
Insufficient Clogged or out-of-place air duct
air volume Bad wiring, out-of-place connections
Blower and motor-related parts Bad contact of brush

Abnormal blower
and motor Loose blower
Blower-related Blower in contact with heater case
Deformed blower
115
1.4 Inspection After Charging Refrigerant
Perform the gas leak test of the refrigerant and the test
run after charging the specified refrigerant volume. Gas Leak Test
1 Gas Leak Test of Refrigerant

This test is performed with the halide torch type
leak detector, but if the electric type leak detector
is used, very small amount of leaks can be
detected. Perform the gas leak test according to
the following procedure:
(1) Conduct the test by selecting a well ventilated

Fig. 22
place wherever practicable, and thoroughly
clean the oil spills at the joints of the charge
hose which occurred at time of charging the
refrigerant.
(2) Especially check the joints of the tubing
carefully.
(3) If gas leaks are found, tighten the joints and
test again.
(4) Be careful not to put your face near the flame If gas leaks, tighten joints.
of the combustion gas of the refrigerant for
long periods because it is poisonous gas.
For the gas leak tester, use a special one for the
refrigerant.
Fig. 23
2 Test Run
Inspect each unit before test run.
(1) Operate the switch and inspect.

(2) Inspect the ON and OFF of the magnetic
clutch of the compressor.
(3) Inspect the compressor belt and the fan belt.
(4) Inspect the radiator cooling water.
(5) In addition, check to see if there is any articles
near the rotating unit and the exhaust
manifold.
After the inspection of each unit is completed to
confirm that there is no abnormality, operate the
cooler and inspect the performance.
The performance is measured by mounting the
Fig. 24
temperature gauge at the inlet port and the
discharge port of the cooler unit and measuring
the air temperature at the inlet and discharge
ports, and by mounting the manifold gauges at the
inlet/ outlet ports, and measuring the inlet and
outlet pressures.
The results are compared with the inspection
data, to judge whether good or bad.
116
(a) Test Conditions
Operate the cooler under the following test
conditions, and measure the pressure and
temperature after 5 ~ 10 minutes after the
discharge temperature has stabilized.
(1) Engine speed is set at 1 500 rpm.
(2) Air volume of the cooler is set at HI.
(3) Air is not blown from the front surface of
the condenser.
(4) Doors are closed and all the windows are
opened.
(5) Test is performed in the shade.
(6) Thermostat dial is set at "COOL" position.
(7) Temperature gauges are placed when
subjected directly to the inlet air and
discharge air.
(8) Two people will stay in the cab and
measure.
(b) Check Against Performance Table

Fig. 25
Test results are compared with the inspection
Dash Type Car Cooler Inspection Data
data.
For example, Fig. 27 shows the inlet air
temperature at 24 ~ 28°C and the discharge
temperature at 8 ~ 13°C when tested at the
ambient temperature is 30°C with the dash
type.
Also the discharge pressure of the compressor
becomes 14 ~ 1 6 kg/cm2 G, and the suction
pressure becomes 1.5 ~ 2.5 kg/cm2 G.
Thus, compare the test results by taking
ambient temperature on the horizontal axis,
and by reading the temperature and pressure
on the vertical axis. If the test results are in
between the read values, then the cooler is
running normal. If the measured values deviate
from the values in between, the case may be
that there is an error in the test or some
trouble in the cooler. In that case, retest or
check again according to the trouble-shooting
procedures.
3 Final Inspection
After completing the test run and before delivering
to the customer, recheck the condition while
referring to the instruction manual.
Fig. 26
117
Machine model Serial No. Cooler No.
Installation date Installed by Measuring date
Cooler Installation and Check
Installation procedure:
1. Installing hoses.
2. Air purging.
3. Gas filling and leakage check.
4. Performance test.
Check items Checked by Remarks

Compressor Compressor oil
Electric circuit
Brackets and bolts
Hose band clamping
V-belt wear and tension
Condenser Hose band clamping

Brackets and bolts
Liquid tank hose
Hose passing angle
Unit Electric circuit

Brackets and clamping bolts
Hose band clamping
Water leakage from heater hose
Fan in unit
Measurement Gas leakage from each device and its connections

High/low pressure
Engine operation at full speed for 60 minutes
118
6-8 Final check of superstructure Detail A
Step 1
Checking the levels a
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
Fig. 1
1 Check the coolant level a in the radiator (See Fig. 1).
If the level is low, refill through the filler ports on the Detail B
b
radiator.
Refer to the OPERATION MANUAL for details.
IMPORTANT:
Do not remove the radiator cap while the coolant is still
hot, as high temperature coolant may gush out of the
radiator causing injury.
Gradually loosen cap b once the coolant temperature
has dropped.
Fig. 2
Check that the coolant level is between the HIGH and
LOW marks on the level gauge. Remove the radiator Detail C
cap and add coolant if the level is low.
c
2 Check the oil levels in all reduction gears for swing
c
reduction devices.
CAUTION:
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels. Fig. 3
Detail D
3 Check the oil level d in the engine oil pan.
CAUTION: d
the oil levels.
4 Check the oil levels e in the final drives. (both sides)

Refer to the OPERATION MANUAL for details. Fig. 4
Detail E
IMPORTANT:
Never stand in front of the final drives when doing this
work.
Loosen the plug by 2 to 3 turns to allow any residual
pressure in the travel device to escape, before fully
e
removing the plug.
If the plug is removed without letting residual pressure
escape, the plug and gear oil may gush from the
machine, causing injury. Do not stand or place your
face directly in front of the plug. Fig. 5
119
5 Check the fuel level in the fuel tank. Detail F
CAUTION:
Handle fuel carefully. Shut the engine off before
fueling. Do not smoke while you fill the fuel tank or
work on the fuel system.
Check fuel level gauge a on the monitor panel. Add

fuel via fill cap b if necessary. The fuel capacity is
Fig. 6
approximately 1 720 liters (454 US gal).
Detail H Detail G
Fuel level
b gauge
Fig. 8 Fig. 7
6 Check the urea levels c and d in the urea tank.

Detail I
CAUTION:
Handle urea carefully. Shut the engine off before
urea. Do not smoke while you fill the uea tank or
work on the Urea system.
Check urea level gauge c on the monitor panel. Add

urea via cap d if necessary. The capacity is
approximately 145 liters (36 US gal).
Fig. 9
Detail K Detail J
Urea level
gauge
Fig. 11 Fig. 10
120
7 Check the pump transmission oil level.
1 Remove dipstick e . Oil must be between the
marks.
2 If necessary, add oil after returning the dipstick to
its original position.
CAUTION:
the oil levels.
Fig. 12
Detail L
Fig. 13
Detail M
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
8 Checking the hydraulic oil level in the hydraulic tank.

Check that the level of oil in the hydraulic tank is
above the range indicated in the oil level gauge.
Fig. 14
Detail N
Note:
Release the air from the main pump at the same
time as you add hydraulic oil. (See page 123 for
details of the air release procedure.)
Fig. 15
121
Step 2
Checking the battery
1 Set the battery disconnect switch and starter

disconnect switch to "ON" .
2 Checking the liquid level of battery.
Fig. 16
Detail O
OFF
ON
OFF
ON
Fig. 17
122
6-9 Releasing the air from the main pumps
Detail A
IMPORTANT:
If the hydraulic pump is not filled with oil, it will be
hose
damaged when the engine is started.
The machine is equipped with three main pumps.

Bleed air from these pumps after add hydraulic oil.
1 Remove air drain hoses a , b , c and d (three for

upper pumps and lower pump) on side of each
pumps.
2 Fill the pump with oil through drain hoses a , b , c Fig. 1
and d port on side of each pumps unctil oil flows
out of drain hoses a , b , c and d .
3 Temporarily tighten drain hoses a , b , c and d Detail B
on each pumps, start the engine and run at slow Front pump
idle. Loosen one of drain hoses a , b , c and d a b
c
slightly until oil flows from plug port to release
trapped air completely. Tighten drain hose. Repeat
d
this step for the rest of hoses.
4 Purge air from the hydraulic system by running the
engines at slow idle and operating the control
levers slowly and smoothly for 15 minutes.
5 Position the machine as illustrated in the oil level
checking procedure.
6 Turn the auto-idle switch off.
7 Stop the engines. Remove the key from the key
switches.
8 Check the hydraulic oil tank gauge. Add oil if
necessary. Rear pump
Lower pump
Fig. 2
1 Retighten drain hoses securely.
Tightening torque of hose: 180 N·m

CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
2 Confirm hydraulic oil level in the hydraulic tank.

Add hydraulic oil if required.
Fig. 3
3 After the oil has flowed out clean the parts carefully.
123
124
6-10 Trial operation of superstructure
Trial operation
1 1 Start the engine.

2 Check the operation of the gauges.
3 Check the travel and swing functions.
CAUTION:
This operation must be done slowly. Avoid abrupt
operation!
4 Check for oil leakage. Confirm that there is no oil
leaking from the assembled areas.
5 Check the amount of oil in the hydraulic tank. If the
oil level is low, add oil through the oil filler port on
the hydraulic tank.
Fig. 1
CAUTION:
Make sure nobody other than the operator is in or on
the hydraulic excavator before starting the operation.
Traveling Fig. 2
2 Confirm that machine noise is maintained at specified

levels.
Fig. 4
Fig. 3
125
6-11 Disassembly procedures for shipment
1. Procedure (Backhoe front)······················································································ 127
126
Detail A
1. P
rocedure (Backhoe front)
Handrail at the O/C top

Right fender work lamp
Right fender mirror Right fender mirror Rear camera parts
assembly (1) assembly (2) Rear light - 2 Bracket - 2 Exhaust pipe parts (T4F)
Fender tank next to the grease tank Rear camera Rear camera harness
Install the bolts, etc.
Ejector Exhaust pipe Bracket to fix the exhaust pipe Muffler cover (T4F)
Install the To be used to install SCR muffler cover SCR muffler cover SCR muffler cover SCR muffler cover SCR muffler cover
installation bolts, the bracket - 4
etc., on the
counterpart side. (Separately pack with air cap sheet.) Bracket - 2 (Bolt, sems J281230)
Rear camera harness
(Bracket 4448039)
Step next to the urea tank Handrail at the grease tank top Handrail at the fuel tank top
(Bolt, sems J271020) (Bolt, sems J271225)
To be used to fix the work lamp harness - 1
To be used to install the rear light - 4
To be used to install the rear camera - 4
(Clip YA0004910) Gasket to install
To be used to fix the work lamp harness - 4 Gasket to install
Install J901640 on the (Clip YA00049110) (Clip YA00049114) (Bolt, sems J271230) the ejector
the exhaust pipe
counterpart side. (Bolt, sems J271025)
Install the To be used to fix the harness - 5 To be used to fix the harness - 6 To be used to install the rear light - 2
Hose reel assembly installation bolts,
To be used to fix the work lamp harness - 5 U bolt assembly - 2
etc., on the (Bolt, sems J271025) (Bolt, sems J271220)
SCR muffler cover SCR muffler cover SCR muffler cover SCR muffler cover Cover fixing bracket
Cover the hose ends with a
counterpart side. To be used to fix the harness - 2 To be used to fix the harness - 7 (Clip, band 4259220) Install the nuts and
plastic bag. Band with tape.
To be used to fix the harness to the rear light - 2 washers.
Install the (Clip, band 4055312)
installation bolts, To be used to fix the rear camera harness

Cover the hose ends with a plastic
etc., on the Scrap the removed
bag and band with tape. Then, use
a wire, etc. to fix to the main body. counterpart side. gasket and ship new
Install the installation one.
bolts, etc. on the Duct assembly on the radiator side Duct assembly on the oil cooler side Dust ejector pipe
counterpart side. Sheet - 1
Plug - 4 Pipe
Mirror assembly next Clamp, hose - 3 Drain pipe
Option to the cab (2) (to be installed also to the bolt side)
WIU antenna Cover with plastic and fix with a masking Tube, plastic Cover fixing bracket Cover fixing bracket Cover fixing bracket Cover fixing bracket
tape. Then, cover with a sheet. Fix with the
rope that is found on the sheet. Use a wire to
render it immobile.
Install the Hose Pipe

installation bolts,
etc. on the
counterpart side. Pipe assembly
*Refer to Note 9. Pipe

To be used to replace the fuel filter Install the band, bolt
Radio antenna Wiper assembly - 2 and nut.
Handle To be used to fix the To be used to fix the To be used to fix the
SCR muffler cover - 20 SCR muffler cover - 10 SCR muffler cover - 54
Install the Install the (Bolt, sems J271030) (Bolt, sems J271225) (Bolt, sems J261030)
installation bolts, installation bolts,
etc. on the etc. on the
counterpart side. counterpart side.
Ascending-descending- Mirror assembly (Washer, plain 4338575) (Washer, plain 4338575)

Tube, plastic
To fix the drain pipe
Chain use lamp assembly next to the cab (1) (Bolt J901495) (Bolt J901435
Install the Bolt, assembly to Bolt, assembly to install Clamp, hose - 3 Clip - 1 Bolt, sems - 4
installation bolts, To be used to fix the DEF pipe at the C/W top (T4F)
Clamp, hose - 3
etc. on the install the duct - 8 the duct (at hinge) - 4
counterpart side.
Protect the antenna with Bracket - 2 Clip 3
Cover the radiator and oil cooler front plastic, etc. (antirust)
with plywood. Turn over the suspending
Turn over the suspending hook to install.
(Plywood installation bolt J901435 - 12)
hook to install.
Handrail next Cab-front step
Bolt, sems – 5
to the cab
Opening
Install the installation
Install the bolts, etc. on the
installation bolts, counterpart side.
etc. on the
counterpart side.
For 700mm shoe

Ladder - 2
Opening
Remove the handrail next to
the cab only from the left side
of the machine.
Apply antirust lubricant.

Handrail at the battery box top Install the pins.
Handrail at the hydraulic tank top Cover (R)
(7059399)
Nut - 4 Cover (L)
(7059400)
Install the installation Side frame tightening
bolts, etc. on the Cap - 4 bolt - 52
counterpart side. Install the
installation bolts
O-ring - 4/8 on the counterpart
Plug - 2 Side frame tightening side.
Fender mirror spacer - 52
assembly next to Frame, side (L),
Install the installation Plug - 2
the cab Frame, side (R)
bolts, etc. on the Rotating upper structure, main body
counterpart side.
Bracket - 4
Counterweight Fix the pilot hose
with clip band.
Slide ladder Washer to tighten CW - 10 Washer - 8
Install the handrail coupling plate on the fender. Plug - 2
Install bolts, etc. on the plate.
Fender next to the cab Fender next to the hydraulic oil tank
(Washer J222016) Bolt - 8
Fender next to the pump (Bolt J921660) Plug - 2
(Spacer 4322539)
Fender installation
To be used to fix the slider harness
bolt assembly - 10 Nut - 8
Install J901640 on
Plug - 4
(Clip YA00049110)
the counterpart side. (Washer J222016) NOTE
To be used to fix the slider harness (Bolt J921650)
1. This drawing shows how to disassemble EX1200- 7B inside the
Install the limit Fender installation factory for shipment.
O-ring - 4/8
(Bolt, sems J271045) switch and related bolt assembly - 12
parts. STD track guard Full track guard 2. Disconnect the battery disconnection switch before disassembly.
3. For covers, plugs and other such necessary parts for packaging,
(Washer J222016)
700G shoe (standard)
(Bolt, sems J271025)
(Bolt J921665) Washer to tighten bolt - 10 Not need to use those contained in “base machine shipment parts” kit no.
Slide ladder installation remove the travel Fix with wire. 900G shoe 9106314 (item numbers in  in the drawing).
bolt assembly - 6 motor cover. 4. Cover the electric wiring connectors with plastic bag. Band with a
Install J901640 on the (Bracket 4336875 Install J901640 on clip band or tape.
counterpart side. To be used to fix the slider harness the counterpart side. Install J901640 on 5. Rust-proof around all bolts, frame coupling parts, screw holes,
the counterpart side.
machined surface, etc. For details, refer to HGS900-024.
6. Grease up the track link and make it taut.
7. Refer to design instructions concerning the density of the anti-
freeze that you will pour inside the engine.
8. After disassembly, replenish the base machine with hydraulic oil.
· Hydraulic oil level: 100mm from the top of hydraulic oil tank
9. If you are using a machine with a cab-front guard, install the wiper
assembly to the cab before shipping.
10. Install “bracket at the track bottom” kit no. 9207237 to the bottom of
the track center frame (item numbers in * in the drawing).
11. At the time of shipment, the light oil level in the fuel tank should be
250L or less.
Fuel level from the top of oiling port:
More than 1720 mm (for the oiling port cap with a key)
More than 1770 mm (for the oiling port cap with no key)
Procedure
Fig. 1
EX1200-7B (Backhoe front) +++++++
127
MOUNTING PROCEDURE FOR

BACKHOE FRONT-END ATTACHMENT
ATTACHMENT
7. Mounting procedures for backhoe front
7-1 Preparation
ASSEMBLY CHART OF BACKHOE FRONT
Fig. 1
Step 1
Parts required (XF60005085)

Item Part No. Part name Q'ty Remarks
00 XF10014767 BE Boom 7.55 m 1 7.55 m
02 4665310 Boom cylinder 2
04 XF10014768 BE Arm 3.4 m 1 3.4 m
11 4485883 O-ring 2
12 4487692 O-ring 2
16 4691360 Hose 2
17 4691369 Hose 2
18 4673718 Hose 1
19 4673719 Hose 2
21 4720028 Hose 2
22 4720037 Hose 2
23 4720029 Hose 1
24 YA00002162 Hose 2
25 YA00002206 Hose 2
26 4720039 Hose 1
30 XF10014769 Lamp, Head 1
31 YA00049110 Clip 3
32 J271016 Bolt, Sems 2
33 J271025 Bolt, Sems 1
P 4508805 O-ring 20
Q 4510169 O-ring 24
Item Part No. Part name Q'ty Remarks

R — Bucket 7.0 m3 1
131
Step 2 Detail A
Preparation of the boom
1 1 Place wooden blocks under the boom 00 as shown

in Figs. 2 and 3.
BE Boom 7.55 m 00 weight: 11 600 kg (25 573 lb) Fig. 2
Wooden block: 2 pcs. 00

Size: 1 000 mm (L) × 500 mm (W) × 800 mm (H)
(40 in) (20 in) (30 in)
b
2 Clean the pin holes a of the boom foot indicated
by .
a
3 Clean the pins b for the boom cylinder indicated
by .
Wooden block
4 Extract the with spacer e pins b , indicated by
as shown in Fig. 6. Fig. 3
Detail B
2 Installation of the boom cylinders 02 Wire rope
10 mmø ×
1 Clean the pin holes c and d of boom cylinder 02 5 000 mm Wire rope
indicated by . 10 mmø ×
2 000 mm
2 Attach wire ropes and a chain block to the boom
c Chain block
cylinder 02 as shown in Fig. 4.
Boom 02 cylinder weight: 1 130 kg (2 491 lb) × 2

02 Boom cylinder Wire rope
Wire rope: 3 pcs. 10 mmø ×
10 mmø × 5 000 mm (L) : 1 pc. 2 000 mm
(0.4 inø) (195 in L)
10 mmø × 2 000 mm (L) : 2 pcs.
(0.4 inø) (78 in L) d Fig. 4
Chain block: 1 pc.

for 2 tonne (2.2 US ton) load Lift & move
3 Lift the boom cylinder 02 as shown in Figs. 4 and 5. b c

4 Move the boom cylinder to the pin hole f
02
indicated by on the boom.
3 Align the pin holes f and c indicated by for

inserting the spacer e .
Detail C Fig. 5
b f
Hold
Boom b
cylinder c
Spacer e
c
Outside Inside Fig. 6
Fig. 7
132
Hold
4 1 Align the pin holes a and b indicated by a
for inserting the pin. b
Note:
Grease the pin before inserting. D
2 Tighten the pin with 2 bolts, 2 spring washers, 1
plate and 1 spacer.
Note:
Apply lubricant to the bolts before installing.
Tightening torque of M20 bolt: 400 N·m Fig. 8

(40 kgf·m/290 lbf·ft) Section D
Bolt & Boom cylinder
spring
washer
Plate
Outside Inside
Pin
5 1 Support the rod side of the boom cylinder, using

Spacer
the lever block and wire rope as shown in Figs. 10 e
and 11. Fig. 9
Lever block: 2 pcs. Detail E

for 1 tonne (1.1 US ton)
Wire rope: 4 pcs. Lever block

10 mmø × 3 000 mm (L)
(0.4 inø) (117 in L)
Shackle: 4 pcs. Boom cylinder

for 1 tonne (1.1 US ton)
2 Take off the crane wire ropes and chain block Wire rope
10 mmø ×
lifting the boom cylinders. (Fig. 11) 3 000 mm Fig. 10
Take off the crane

wire ropes and
chain block
Fig. 11
133
6 Connect the boom cylinder hoses 16 and 17 indicated
a
by . (Figs. 12 and 13)
Tightening torque of hose 16 : 270 N·m

b
Tightening torque of hose 17 : 180 N·m

Boom cylinder hoses
Notes:
i) When connecting hoses, do not twist them, or Detail F
their service life will be shortened.
ii) Connect the hoses so as not to make contact
with other parts.
iii) Make sure that there is no dust sticking to the
seat faces of the hoses.
iv) Pay attention not to damage the joining surfaces O-ring Q
of the hoses. O-ring P
v) Use O-rings Q (P/No. 4510169~2) and P (P/No.
4508805~2) to install the hoses. Apply a thin Hose 17 O-ring Q
layer of sealant #98D to the O-rings before
installation. Hose 16
The other boom cylinder should also be installed in O-ring P

the same manner as the above.
Fig. 13
7 Boom lamp installation Detail G
1 Install a lamp 30 in the boom.

30
Lamp 30 weight: 1.17kg
(2.58 lb)

Bolt
(14 kgf·m/103 lbf·ft) J901430
Notes:
i) The lamp mounting bolt possesses boom.
ii) When you connect harness, connect the same
line-colored harness.
8 After the oil has run out, clean the parts carefully. Washer
J222014
Fig. 14
134
9 1 Connect the grease hoses a indicated by . Detail H

a
Notes:
i) When connecting hoses, do not twist them, or
with other parts. Boom cylinder
seat faces of the hoses. Fig. 15
iv) Pay attention not to damage the joining surfaces
of the hoses.
The other grease hose should also be installed in

2 After the grease has run out, clean the parts Fig. 16
carefully.
10 Remove urethane foam sleeve b , fitted as protection Detail I

on the plated boom cylinder rods.
Plated
cylinder rod
Boom cylinder
Urethane
foam sleeve b
Fig. 17
135
11 1 Connect the 1 hose 18 and 2 hoses 19 to the boom
piping.
Notes:
i) Make sure that there is no dust sticking to the
O-ring P
ii) Pay attention not to damage the joining surfaces
of the hoses.
19
iii) Use O-rings Q (P/No. 4510169~2) and P (P/No. O-ring Q
4508805~1) to install the hoses. Apply a thin
layer of sealant #98D to the O-rings before 18
installation.
19
Tightening torque of hose 18 : 1 pc. 180 N·m
Fig. 18
Tightening torque of hose 19 : 2pcs. 270 N·m

2 Leave the free end of the installed hoses covered.
Arm cylinder
3 After the oil has run out, clean the parts
carefully.
12 Secure the arm cylinder rod with wire ropes and a lever
block, as shown in Figs. 19 and 20. Fig. 19
Wire rope: 2 pcs. Detail J

Wire rope
10 mmø × 5 000 mm (L)
Lever block
(0.4 inø) (195 in L)
Lever block: 1 pc.

for 3 metric tonne (3.3 US ton) load
Wire rope
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being extended. Be
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident. Fig. 20
Note: Detail K
The lever block secure the arm cylinders and Urethane
prevent the cylinder rods from extending during the foam sleeve a
work. Arm cylinder
13 Remove urethane foam sleeve a , fitted as protection

on the plated arm cylinder rod.
Plated
cylinder rod
Fig. 21
136
Step 3
Preparation of the arm 04
1 Place wooden blocks under arm 04 as shown in Fig.

22.
Arm 04 weight: STD. 3.6 m 6 130 kg (13 485 lb)

BE 3.4 m 6 300 kg (13 860 lb)
Wooden block: 2 pcs.

Size: 500 mm (L) × 1 000 mm (W) × 500 mm (H) Wooden
block
(20 in) (40 in) (20 in)
Note:
Each wooden block must be able to carry a load of Fig. 22
at least 3 500 kg (7 700 lb).
2 1 Clean off the anticorrosive from the pins a and b

inserted into the arm top. Bucket cylinder
2 Extract the pins a and b from the arm top.
3 Clean pin holes a and b . c
4 Clean off the anticorrosive applied to the pins c
inserted into the arm. b
5 Remove grease hoses attached to pins c .
6
a
Extract pins c from the arm.
7 Clean pin holes c and d in the arm.
d
Fig. 23
3 Remove urethane foam sleeve e , fitted as protection Detail L

on the plated bucket cylinder rod. Urethane
foam sleeve e
Bucket cylinder
Plated
cylinder rod
Fig. 24
137
4 Fix bucket cylinder rods with wire ropes and a lever
block as shown in Figs. 25 and 26. Bucket cylinder
Wire rope: 2 pcs.

10 mmø × 5 000 mm (L)
(0.4 inø) (195 in L)
Lever block: 1 pc.

for 3 metric tonne (3.3 US ton) load
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being extended. Be Fig. 25
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident. Detail M
Wire rope
Lever block
Note:
The lever blocks secure the bucket cylinders and Wire rope
prevent the cylinder rods from extending during the
work.
Bucket cylinder
Fig. 26
138
Step 4 a ×2 b ×2
Preparation of the bucket
1 1 Position bucket R . R
Bucket R weight: 7.0 m3 7 860 kg (17 328 lb)
2 Clean pin holes a × 2 and b × 2, as shown in Fig.

27.
Fig. 27
2 Remove Covers a and b to show it in Fig. 28. View N
Tightening torque of M22 Bolt : 550 N·m

(55 kgf·m/400 lbf·ft) Cover a
Cover b
Fig. 28
3 Reinstall the pins a and b removed from the arm, as View O

shown in Fig. 29.
Pin a
Pin b Fig. 29
4 Apply grease to the bucket pin holes and the View P

connecting surfaces of the arm end and link Apply grease
(a total of 4 locations).
Apply grease
Fig. 30
139
140
7-2 Mounting of backhoe boom
Step 1
Mounting of the boom
1 1 Clean off the anticorrosive applied to the pins

inserted into the boom-jointing portion of the main
frame.
2 Extract the 2 pins a and b indicated by ,
from the main frame.
Fig. 1
3 Apply grease to the above-described pin holes.
Detail A
b
Detail C a
Front side Rear side
Shackle
Shackle
Main frame
Fig. 2
Detail B
Lift
Fig. 4
Wire rope
24 mmø × Wire rope
10 000 mm 24 mmø ×
10 000 mm
2 1 Put on the boom, attach wire ropes and a chain 00

block to boom 00 as illustrated in Figs. 3 and 4.
2 Lift the boom so that the pin holes c indicated by

become horizontal.
c
Note:
Level the boom by adjusting the preset chain blocks.
c
CAUTION: Fig. 3
Never allow anybody to stand directly beneath the lifted Lift

boom.
BE boom 00 weight: 13 860 kg (30 556 lb)
Wire rope: 4 pcs.

24 mmø × 5 000 mm (L) : 4 pcs.
(0.95 inø) (195 in L)
c
Shackles : 4pc
for 5 tonne load (5.5 US tonne load)
Fig. 5
141
Lift & move
3 Lifting the boom, move it horizontally to the holes a
indicated by on the main frame.
Cab
Notes: b a
i) When moving the front, be careful not to
let it touch the cab on the superstructure.
ii) It is safe to attach a rope on part
indicated by to guide it.
Rope
Rope: 1 pc. 8 mmø × 5 000 mm
8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L)
Fig. 6
Lift
D
4 1 Align the pin holes a and b indicated by
a
for inserting the pins. b
2 Grease the pins before inserting.
Adjust a clearance between the frame and boom

by reference to the instructions on pages 191
and 192.
Fig. 7
5 Tighten the 2 pins with 4 bolts, 4 spring washers and 2 Section D
plates.
Pin
Note:
Plate
Bolt &
(40 kgf·m/290 lbf·ft) Shim spring
Width across flats: 30 mm washer
Fig. 8
6 1 Place 1 wooden block c , about 200 mm (8 in) in

height, on the ground where the arm top is placed. Take off the crane wire ropes
Lower
Wooden block c : 1 pc.
size: 1 000 mm (L) × 300 mm (W) × 200 mm (H)
(40 in) (12 in) (8 in)
2 Lower the front so that the arm top rests on the

wooden block.
c
7 Take off the crane wire ropes and chain blocks lifting Wooden
block
the boom assembly.
200 mm (8 in)
Fig. 9
142
Step 2
Connection of the hoses to basic machine and boom Hose 21 ~ 26
1 1 Before doing this work, do not forget to release

the pressure in the hydraulic tank.
2 Then remove the blind covers from the pipe ends.
2 Connect the hoses 21 ~ 26 to the basic machine and

boom.
Notes:
with other parts.
Fig. 10
iv) Pay attention not to damage the joining surfaces Detail E
of the hoses. O-ring P : 22 23 24
25 22 24 23
v) Use O-rings Q (P/No. 4510169~5) and P (P/No.
4508805~5) to install the hoses. Apply a thin
installation.
Tightening torque of hose 22 23 24 : 180 N·m

Tightening torque of hose 21 25 25 : 270 N·m

26 22 24 21
O-ring Q : 21 25 26 Fig. 11
3 Close the air-vent cock on the hydraulic tank. After

the oil has drained, clean the parts carefully.
143
Step 3 Boom cylinder
Installation of the boom cylinders
1 1 Extract 2 pins from part a indicated by .

2 Carefully clean the pin holes a and b indicated b
by .
3 Apply grease to parts a and b indicated by a
.
Fig. 12
Detail F
c
Lever block
Boom cylinder
Boom cylinder (R)
(L)
Fig. 13
2 1 Lower the boom cylinder slowly with the lever block

c until the pin hole of the boom cylinder rod b
aligns with a indicated by on the main
frame (Figs. 13 and 14).
a
2 Start the engine and extend the rod end of the b

boom cylinder.
Fig. 14
144
3 1 Align the pin holes a and b indicated by
for inserting the pin.
b
Note: a
Grease the pins before inserting.
Adjust a clearance between the frame and boom

cylinder by reference to the instructions on
pages 191 and 192. Fig. 15
Detail G
2 Tighten the 1 pin with 2 bolts, 2 spring washers

and 1 plate.
Pin
Note:
Pin
Tightening torque of M20 bolt: 400 N·m Fig. 16
a b
Fig. 17
H
Section H
Pin
Shim
Plate
Bolt &
spring
washer
Fig. 18
The other boom cylinder should also be installed in

145
4 Connect the grease hoses a and b indicated by
.

Notes:
their service life will be shortened
Fig. 19
with other parts.
Detail I
Boom cylinder
of the hoses.
a
5 After the grease has run out, clean the parts carefully.
b
Grease hose a Grease hose b
Fig. 20
6 Remove the lever blocks used to fix the arm cylinder in

"Step 2- 12 " on page 136. Arm cylinder
Fig. 21
Detail J
Wire rope
Lever block
Wire rope
Fig. 22
146
Step 4
Detail K
Greasing (2)
1 The machine is provided with a electrially operated

grease lubricator connected to the hose reel and a
grease gun.
(1) Pull out the grease hose from hose reel b while
holding grease gun a .
(2) Stop pulling out when the reel clicks and desired
hose length is obtained the hose will be locked b
automatically. a
(3) Connect grease gun a to the desired grease fitting
and pull the gun lever grease will be supplied
automatically by air pressure.
Fig. 23
IMPORTANT:
Run the engine at medium speed or more when
supplying grease using the lubricator.
2 Start the engine.
3 1 Supply grease to 2 points as shown in Figs. 24 and

25.
2 Supply grease to 5 points as shown in Figs. 26 and
27.
Notes: Fig. 24

speed above medium speed. Detail L
iii) Insufficient greasing will wear the pins.
BOOM CYL.
ROD
Fig. 25
Detail M
BOOM CYL. BOTTOM

ARM CYL. BOTTOM
Fig. 26
BOOM CYL. BOTTOM

BOOM FOOT
BOOM FOOT
Fig. 27
147
4 Lubrication method

grease gun a .
IMPORTANT:
a
(3) Press hydro-chuck d protruding from high-pressure

d
grease gun a into a grease nipple and pull the
c
lever to discharge grease.
a

Fig. 28
IMPORTANT:

pump, and the hose so as to ensure long life of the
e
this time.
Note:
hose.
148
Step 5
Raise
Air bleeding of boom and arm cylinders
Lower
CAUTION:
Make sure that nobody other than the operator is in or
on the hydraulic excavator.
2 Idle the engine sufficiently to release the air in the
hydraulic system.
3 Check for unusual vibration or noise.
4 Operate each cylinder a few times to bleed the air
in the hydraulic system, according to the following Fig. 30
procedure.
Retract
Note:
Extend
The engine speed should be kept as low as
possible.
2 Procedure
Action
1 Start the engine. Fig. 31
Note:
Run the engine at low speed.
2 Move each cylinder back and forth five times.
Notes:
i) Avoid moving the cylinder suddenly or quickly, or
the seals may be burnt.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end during the first four cycles.
iii) Move the cylinder at full stroke on the fifth cycle.
3 Hold the cylinder at the stroke end for a minute to

apply relief pressure and bleed the air from the
cylinder. Repeat the procedure twice.
4 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to next page)
149
3 Bleeding locations
CAUTION:
Take all reasonable precautions as this work is to be conducted high above the ground.
4 1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION:
Take care to prevent anybody from starting the engine during the work.
3 Follow the procedures outlined below to release air from the cylinders, by way of each of the
bleeders indicated by .
1) Remove the rubber cap.

2) Loosen the plug. Arm cylinder
3) A mixture of air and hydraulic air will escape

Boom cylinder
from the bleeder.
4) Continue bleeding until only oil escapes.
Boom cylinder
5) Tighten the plug securely.
Arm cylinder
6) Replace the rubber cap.
Fig. 32
Detail N
Fig. 33
Detail O
5 Recheck the oil level in the hydraulic tank. If the oil

level is low, refill the tank. Level check
Fig. 34
150
7-3 Mounting of arm
Step 1
Installation of the arm a
1 1 Clean off the anticorrosive b

from the pin a inserted into
the boom top. 3 500 mm
(135 in)
2 Extract the pin a indicated
c
by from the boom
top. Fig. 1
3 Clean the pin holes a , b and c indicated by
.
4 Apply grease to parts a , b and c indicated by
.
5 Raise the boom top about 3 500 mm (135 in)
above the ground. Scaffolding
3 500 mm
(135 in)
2 500 mm
2 Set the scaffoldings about 2 500 mm (100 in) high on
(100 in)
both sides of the boom top.
Fig. 2
Scaffoldings: 2 sets, 2 500 mm (100 in) high

Detail B
Detail A
3 1 Put shackles on the eye-plates provided for lifting Lift
Wire rope
the arm 04 and attach wire ropes to the shackles.
(Figs. 3, 4 and 5) Shackle
Detail C
Wire rope
BE Arm 04 weight: 3.4 m 6 540 kg (14 419 lb) 26 mmø ×
Wire rope 8 000 mm
Shackle: 2 pcs. Eye plate
Fig. 3
for 5 tonne load (5.5 US tonne load) Shackle
Wire rope: 2 pcs.

26 mmø × 8 000 mm (L) Shackle
(1.0 inø) (312 in L)
Eye plate
Fig. 4 04
2 Lift the arm so that the pin holes c indicated by

become horizontal.
c
Note: Fig. 5
Level the arm by adjusting the preset Lift
chain blocks.
CAUTION:
Never allow anybody to stand directly
beneath the lifted arm.
Fig. 6
151
4 1 Lift the arm as shown in Fig.7.
2 Move it to the pin hole a , indicated by
Lift & move
of the boom end.
Note:
It is safe to attach a rope on part
indicated by to guide it.
Wire rope: 1 pc.
8 mmø × 5 000 mm (L) b a
(0.3 inø) (195 in L)
Rope
8 mmø × 5 000 mm
Fig. 7
5 1 On the scaffoldings provided, align the pin holes Hold

a and b indicated by for inserting the pin.
2 Thereafter, do the work around the parts a and
b indicated by on the scaffoldings.
3 Grease the pin before inserting.
D
CAUTION:
Handle the pin with the utmost care since it is quite
heavy. a b
Pin weight: 179 kg (395 lb)
Scaffolding
4 To prevent the pin from coming out, attach it with
2 bolts, 2 spring washers and 1 plate.
Fig. 8
Note: Section D
Apply lubricant to the bolts before installing. Bolt &
spring
Tightening torque of M20 bolt: 400 N·m washer
Plate
CAUTION:
Pay full attention to safety since the work is done at a
high place.
Pin
Fig. 9
6 1 Place a wooden block on the ground where

Lower
the arm top is lowered.
2 Lower the crane and boom together so that
the arm top rests on the wooden block.
Wooden block: 1 pc.

size:
1 000 mm (L) × 300 mm (W) × 200 mm (H)
(40 in) (12 in) (8 in)
200 mm
(8 in)
Fig. 10
152
7 Connect the arm cylinder Detail E
Lift
1 Attach wire ropes to the arm cylinder. Wire rope
8 mmø ×
5 000 mm
Wire rope: 2 pcs. each being
8 mmø × 5 000 mm (L) Arm cylinder
(0.3 inø) (195 in L)
2 Hold the arm cylinder with a crane.

Fig. 11
3 Cut the wire ( a indicated by ) used to fasten
the arm cylinder at the time of shipping.
b
a
8 1 Lift the arm cylinder a little by a crane.

2 Remove the sleeper at part b indicated by .
Fig. 12
9 1 Lift the arm cylinder a little further by a crane so
Hold
that the center of the pin hole of the arm cylinder
rod and that of the arm bracket, indicated by d
Arm cylinder
are in line.
2 Extend the arm cylinder rod slowly in the direction c
of the arrow . d
3 Align the center of the pin holes of the arm cylinder
rod c with that of the arm bracket d indicated by
.
4 Install the pin.
5 Grease the pin before inserting.
Section F
Bolt &
spring
washer
Fig. 13
Pin Plate
Fig. 14 c d
Pin welght : 58.4 kg (129 lb)
6 Tighten the 1 pin with 2 bolts 2 spring washers and

1 plate.
F
Note:
Apply lubricant to the bolts before tightening.

Fig. 15
153
10 1 Prior to the connection of the hoses, release the air Detail G
pressure in the hydraulic tank.
2 Then remove the blind covers from the pipe ends.
3 Connect the hydraulic hose for the bucket cylinder
at part 18 and 19 indicated by . Hose 18
Hose 19
Notes:
ii) Connect the hoses so as not to contact other
parts.
seat faces of the hoses. Fig. 16
of the hoses.
v) Use O-rings Q (P/No. 4510169)~1 and P (P/No.
4508805)~2 to install the hoses. Apply a thin
installation.
Tightening torque of hose 18 : 1 pc. 180 N·m

Tightening torque of hose 19 : 2 pcs. 270 N·m

4 Close the air-vent cock on the hydraulic tank.

Fig. 17
Detail H
11 Remove the lever blocks used to fix the bucket cylinder
Wire rope
in "Step 3- 4 " on page 138.
Lever block
Wire rope
Bucket cylinder
Fig. 18
154
12 1 Connect grease hose to parts a indicated by Detail I
.
2 Connect grease hoses at part b and c indicated
by .
Tightening torque of hose: a , b 30 N·m

Width across flats: 19 mm a
Tightening torque of hose: c 80 N·m

Notes: c
with other parts.
iii) Make sure that there is no dust sticking to the Fig. 19
iv) Pay attention not damage the joining surfaces of
the hoses.
3 After the grease has run out, clean the parts

carefully.
Detail J
b Fig. 20
Fig. 21
155
Step 2
Greasing (3) Detail K

grease gun.
hose length is obtained the hose will be locked
automatically. b
(3) Connect grease gun a to the desired grease fitting a
Fig. 22
IMPORTANT:
2 Start the engine.
3 Supply grease to 4 points as shown in Figs. 23 and 24.
Notes:
iii) Insufficient greasing will wear the pins.
Fig. 23
Detail L
ARM CYL. ROD PIN

BUCKET CYL. BOTTOM PIN
BOOM AND ARM JOINT PIN
(RIGHT)
BOOM AND ARM JOINT PIN
(LEFT)
Fig. 24
156

grease gun a .
IMPORTANT:
a

d
c
a

Fig. 25
IMPORTANT:

e
this time.
Note:
hose.
157
Step 3
Air bleeding of the arm and bucket cylinders

Roll out
Retract
Extend
Roll in
CAUTION:
Make sure that nobody other than the operator is in or
on the hydraulic excavator.
hydraulic system.
3 Check for unusual vibration or noise. Fig. 27

in the hydraulic system, according to the following
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
158
3 Bleeding locations
CAUTION:
Take all reasonable precautions as this work is to be conducted high above the ground.
4 1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION:
3 Follow the procedures outlined below to release air from the cylinders, by way of each of the
bleeders indicated by .
1) Remove the rubber cap. Arm cyl.

2) Loosen the plug.
3) A mixture of air and hydraulic air will escape Arm cyl.
from the bleeder.
Bucket cyl.
5) Tighten the plug securely.
6) Replace the rubber cap.
Bucket cyl.
Fig. 28
Detail M
Fig. 29
Detail N
5 Recheck the oil level in the hydraulic tank. If the oil

level is low, refill the tank. Level check
Fig. 30
159
160
7-4 Mounting of bucket
Step 1
c
Mounting of bucket
a
b
1 1 Position bucket R .
2 Clean the parts a , b , c and d indicated by

.
3 Apply grease to the parts a , b , c and d d
indicated by .
R
Fig. 1
Detail A
Lift
Detail B
Shackle
Wire rope
22 mmø ×
10 000 mm Wire rope
22 mmø ×
10 000 mm
R
Fig. 3
2 1 Put on the bucket, and attach wire ropes and

shackles to the bucket.
2 Lift the bucket as illustrated in Figs. 2 and 3.
Note: Fig. 2
Level the bucket by adjusting the preset chain
blocks. Lift
Arm
CAUTION:
Never allow anybody to stand directly beneath the lifted
bucket.
Bucket R weight:
150°~160°
7.0 m3 : 7 860 kg (17 328 lb)
Wire rope: 2 pcs.

22 mmø × 10 000 mm (L)
(0.85 inø) (390 in L) 2 000 mm
(78 in)
Shackle: 2 pcs.
for 5 tonne load (5.5 US tonne load)
Fig. 4
Lift & move
3 Raise the arm top 2 000 mm (78 in) above the
ground.
4 Lift the bucket so that the pin holes a and d
indicated by become horizontal.
a d
5 Move the bucket to the pin hole d indicated by
on the arm top.
Fig. 5
161
3 1 Align the centers of pin holes a and b in order to Hold
insert the pins (both sides).
Notes:
a
i) Do not force the pins in, as doing so can cause b
the dust seal to break.
ii) Apply grease to the pins before installation.
2 Tighten the 10 bolts, 10 spring washers. (both

sides)
C
Tightening torque of M20 bolt : 400 N·m
(Bolt a ) (40 kgf·m/290 lbf·ft)

(Bolt b ) (75 kgf·m/550 lbf·ft) Section C
Width across flats: 32 mm Assemble the same Bolt ~10
parts to both sides. Spring washer ~10
Note: Pin
Detail D
11
Fig. 7
Fig. 8
3 After inserting the pins, position 2 O-rings 11 in the

groove and tighten their nuts.
Tightening torque:
Assemble so that no gap is provided here.
(Bolt size: M5)

Note: Slit
10 ~ 20 10 ~ 20
Carefully seat 2 O-rings 11 on the boss arm and
bucket as shown in Figs. 8 and 8-a.
Double nut Double nut

Note:
To ease the assembly, the bolt has been made 11
slightly long. After assembly, cut the bolt to 10 ~ Assemble so that no
gap is provided here. Fig. 8-a
20 mm for usage.
162
4 1 Lower the bucket with a crane so that the bottom of Take off wire ropes from crane.
the bucket rests on the ground.
2 Take off wire ropes from the crane and chain
blocks lifting the bucket.
Lower
Fig. 9
5 Set the boom and arm at 120° to 140°.
120° to 140°
Fig. 10
163
6 1 Extend the bucket cylinder in the direction
of arrow to align the centers of the link
pin hole a and the bucket pin hole b , as
shown in Figs. 12 and 13.
2 Align the centers of the pin holes of the link
and bucket.
3 Grease the pins and insert.
4 To prevent the 1 pin from coming out,
secure them with 10 bolts, 10 spring
washers (see Fig. 15).

(Bolts a ) (40 kgf·m/290 lbf·ft) Fig. 11
Detail E Detail F
Bucket cylinder
(Bolts b ) (75 kgf·m/550 lbf·ft)
Note:
Apply lubricant to the bolts before tightening.
a
5 After inserting the pins, position 2 O-rings
12 in the groove and tighten their nuts. a
b
b
Tightening torque:
Assemble so that no gap is provided here.
Fig. 12 Fig. 13
Note:
Carefully seat 2 O-rings 12 on the boss arm and
bucket as shown in Figs. 16-a and 16.
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to 10 ~
20 mm for usage.
(Bolt size: M5) G
10 ~ 20 Slit 10 ~ 20
Fig. 14
Double nut Double nut
Detail G
12
Assemble so that no Pin
gap is provided here. Fig. 16-a
Detail H
12
Bolt ~10
b Assemble the same Spring washer ~10
parts to both sides.
Fig. 16 Fig. 15
164
7 Install lubricator hoses (option)
1 Install lubricator hoses.

(hose a b e g h ) (3 kgf·m/22.1 lbf·ft)

(Bolts c d f ) (4 kgf·m/29.5 lbf·ft)
Fig. 17
Note:
When you attach hose, attach it so that there is not Detail I
distortion.
2 After the grease has run out, clean the parts d

carefully.
a b e f
Lift side Fig. 18
Detail J
Right side Fig. 19
Detail L Detail K
Bucket cylinder
h
Bucket cylinder
g
Arm, bucket interval Fig. 21 Link bottom Fig. 20

165
Step 2
Greasing (4) Detail M

grease gun.
hose length is obtained the hose will be locked
automatically. b
(3) Connect grease gun a to the desired grease fitting a
Fig. 22
IMPORTANT:
Note:
Bucket and Link Pins
Cap Head
Each grease fitting is provided with a protective cap.
Remove cap as shown below before greasing.
Removing/installing procedure:
Insert a screw driver into the cap cavity along the
arrow "a" direction, and scoop out the cap by
applying force in the arrow "b" direction.
When installing, push the cap by hand in the arrow
"c" direction until it bottoms or tap using screw driver Grease Cavity
Fitting
grip.
Cap Screw
Pin
Driver
Fig. 23
2 Start the engine.

Detail N
R/H & L/H Bucket cyl. rod pin

3 Supply grease to 8 points as shown in Fig. 24.
R/H & L/H Link pin
Notes:
i) When using a lubricator, increase the engine R/H & L/H Link pin
iii) Insufficient greasing will wear the pins. R/H & L/H Arm top pin
Fig. 24
166

grease gun a .
IMPORTANT:
pump a will be mixed in, making grease turn whitish.
a

d
c
a

Fig. 25
IMPORTANT:
• Slowly detach hydro-chuck g from nipple e .

e
this time.
Note:
hose.
Detail O
6 Check if all the tightening bolts at the backhoe front are

securely tightened.
Fig. 27
167
Step 3 Raise
Air bleeding of cylinders

Roll out
Roll in
Lower
Roll out
CAUTION: Roll in
Make sure that nobody other than the
operator is in or on the hydraulic
excavator.
Fig. 28
hydraulic system.
3 Check for unusual vibration or noise.
in the hydraulic system, according to the following
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
168
Step 4
Bleeding locations
CAUTION:
As this work is to be conducted at a height, take due safety precautions.
1 1 Set the front-end attachment on the ground in the position illustrated below (Fig. 29).
2 Stop the engine.
CAUTION:
3 Following the procedure outlined below, release the air from the cylinders, by way of the bleeding
locations indicated by .
1) Remove the rubber cap.

2) Loosen the plug.
3) Air and hydraulic oil will escape together.
5) Tighten the plug securely to its original position.
6) Replace the rubber cap. Arm cyl.
Arm cyl.
Boom cyl.
Bucket cyl.
Bucket cyl.
Boom cyl.
Fig. 29
Detail P
2 Recheck the oil level in the hydraulic tank. If there is

insufficient oil, refill the tank through the oil filler port.
Position the front-end attachment as illustrated in
Level check
Fig. 26 when checking the oil level.
Fig. 30
Fig. 31
169
170
7-5 Adjustment of track link tension
Swing upperstructure 90° and lower bucket to raise track off

ground as shown.
Keep the angle between boom and arm 90° to 110° and 90° ~ 110°
position the bucket's round side on the ground. Place blocks
under machine frame to support machine.
Rotate track in reverse two full rotations and then forward two
full rotation. A
Fig. 1
Measure distance (L) at middle track frame from bottom of track
View A
frame to back face of track shoe.
Track Sag ( L) Specifications:

530 to 590 mm
(21 to 23 in)
From the bottom of
the frame to the top
of the track shoe
Note:
Check track sag after thoroughly removing soil stuck
on track area by washing.
Fig. 2
Adjusting Procedure:
CAUTION:
High pressure grease. Do not remove grease fitting a
or valve assembly Keep body and face away from
valve.
1 Clean sprocket, track links and grease valve area.
2 To tighten track, connect a grease gun to the

grease fitting a an add grease until the sag is Fig. 3
within recommended limits. Detail B
3 To loosen track turn valve b counterclockwise a Fitting

slowly (use long socket 24). Grease will drain from
grease outlet with valve b loosened 1 to 1.5 turns. CAUTION!
If grease does not drain smooth, slowly rotate the Never touch
track with it raised off the ground.
Be sure to retighten valve b to 88 N·m b Valve
(9 kgf·m/65 lbf·ft) after loosening track.
Grease outlet Fig. 4
IMPORTANT: Detail C
It is abnormal if track is still tight after turning valve b
counterclockwise or track is still loose after charging
grease to fitting a . In such cases, NEVER
DISASSEMBLE the track adjuster. See your authorized
dealer immediately.
Fig. 5
171
172
7-6 Final trial operation check
1 After connecting all the hoses, check that no hose hits Detail A
against other hose or parts.
2 1 Adjust the track link tension appropriately. (See

page 171 "Adjustment of track link tension".)
2 Check all functions of the machine. (See "Checks

after completing the assembly")
3 Recheck the oil level in the hydraulic tank. If there

is insufficient oil, refill the tank through the oil filler
port.
CAUTION:
Before starting, make sure there is no person other
than the operator in the hydraulic excavator.
Note:
After the above procedures 1 and 2 are Fig. 1
completed, carry out work at 60% to 70% of full
power for the first 50 operating hours, before
commencing full-power operation.
Forward Reverse
travel travel
Swing
Right
Swing
Left
Fig. 2
Forward Reverse
travel travel
Raise
Roll out
Roll in Lower
Roll in
Roll out
Fig. 3
173
7-7 Disassembly procedures for shipment
1. Procedure, backhoe front (BE. Procedure) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2. Procedure, bucket .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
174
Detail A
1. Procedure, backhoe front (BE Procedure)

BOOM LIGHT PARTS
MOUNTING BOLT BEING

ATTACHED TO A
COUNTERPART.
Boom ~ Upperstracture (Lower side)
Procedure, backhoe front

Fig. 1
EX1200-7 (BE Procedure) +++++++
175
Detail B
2. Procedure for bucket Washer, spring
Bolt Bushing
press-fitting
press-fitting
Before
Before
Cover
Install at an angle as shown by Washer, spring

a  mark in the drawing. Do the
Bushing
same for the opposite side.
Press-fitting Press-fitting Bolt
direction of bushing direction of bushing
press-fitting
press-fitting
Hole
Shaft
Before
Before
Hole
Cover
Bushing
O-ring
Install at an angle as shown by
Collar a  mark in the drawing. Do Press-fitting Press-fitting
the same for the opposite side. direction of bushing direction of bushing
Hole
Shaft
Hole
Fitting, grease
Bushing
O-ring
Cap
Dust seal assembly

direction
Outside Bushing side

Bucket
Screw, drive Seal, dust
Nameplate
(Actual length)
Side shroud
Shroud
Lock
Shroud
NOTE

Work carefully so that the bushing is pressed in the correct direction.
The imprinting on the nameplate is as follows.
Model: EX1200-7
Front No.: In accordance with instructions given from the production
management dept.
Capacity: 7.0M3
Tooth
Shroud between the teeth
Shroud
Pin, lock
Shroud
EX1200-7 Procedure bucket +++++++

Lock
Fig. 2
177
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
8. Checks after completing the assembly
1 After assembly, clean and wipe each part thoroughly
with a rag.
2 Inspect the excavator before starting the engine.
CYLINDERS AND
HYDRAULIC LINES
Check for oil leaks.
OPERATOR'S CAB
Clean.
UREA TANK
Check DEF/AdBlue® level.
PINS AND BOLTS OIL COOLER

Check for looseness or Check fins.
absence.
Lever
Check coolant level.
RADIATOR
Clean fins.
HYDRAULIC TANK
Check oil level.
ENGINE
Check oil level.
FINAL DRIVE
Check oil level. Fig. 1
(Both sides)
Checks after completing the assembly
1 Electrical system Detail A

Check for worn or frayed wires and loose
connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the Operation
Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after completing
assembly. Fig. 2
181
3 Check the instruments immediately after starting the Detail B
engine. 1 2 3 4 5 6
7
IMPORTANT:
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all 12
8
necessary measures.
CAB FEATURES 9
Std. Model
1 - Left Control Lever/Horn Switch (On Top of Lever)
11
2 - Left Travel Pedal
3 - Left Travel Lever
4 - Right Travel Lever
5 - Right Travel Pedal
6 - Right Control Lever
10
7 - Multi Monitor 13 15 19
8 - Switch Panel
9 - Key Switch
17
10 - Operator's Seat
11 - Cab Door Release Lever 14
12 - Pilot Control Shut-Off Lever
13 - Glove Compartment
14 - Fuse Box
15 - Cigar Lighter 16
16 - Switch Panel (Optional)
17 - Hot & Cool BoxOUTLINE
18 - ENGINE STOP SWITCH
19 - External Power Supply
Fig. 3
Detail C
18
Fig. 4
182
MONITOR PANEL Detail D
OUTLINE
1 2 3 4 5 6
1 - Work Mode Display 10 - Radio Display
2 - Aftertreatment Device Display 11 - Air Conditioner Display
3 - Power Mode Display 12 - Coolant Temperature Gauge 7
16
4 - Hour Meter, Clock 13 - Auxiliary 17
5 - Auto-Lubrication Display (Optional) 14 - Travel Mode Display 15
8
6 - Fan Reverse Display 15 - Auto Shut-Down Display 14
9
7 - Seat Belt Display 16 - Auto-Idle Display
13
8 - Fuel Gauge 17 - DEF/AdBlue® Gauge
9 - Sub Meter Display 12
10
11
Fig. 5
4 Measurement of engine revolutions
Engine speed
Standard sensor
Item
(new machine)
Low idle 850 ± 50
Engine Auto idle 1 400 ± 50
revolution ECO mode 1 700 ± 50
speed PWR mode 1 800 ± 50
-1 High idle
(min ) HP mode
Fig. 6
1 950 ± 50
(ECO Control Suspend)
183
184
9. Checking machine performance
The figures and tolerances listed below are for new machines.
The measurements should be performed under the following
Note:
conditions:
Measure each actuator speed after sufficiently
· Engine speed: Maximum
operating the machine.
· Hydraulic oil temperature: 50° ± 5°C
· Site: Firm level ground
TRAVEL SPEED (20M TEST RUN)
1 Preparation
Fig. 1
2 Measurement
Preliminary run Test run 20 m Preliminary run Machine at rest

7~9m (65.6 ft) 7~9m
(23 ~ 30 ft) (23 ~ 30 ft) Fig. 2
3 Determination Front
Unit: sec.
FORWARD
Item Standard
20 m (Low) 31.5 ± 2.0
20 m (High) 22.0 ± 1.6

REVERSE
185
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
Fig. 3
1 Mark any one of the track shoes on the side where

this test is to be performed.
2 Jack up the track to be tested. (Fig. 3)
2 Measurement
1 Accelerate the engine to maximum speed.
2 Measure the time required to make three full turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
3 Determination
Unit: sec.
Item Standard
Track link speed/

64.0 ± 4.0
Forward 3 rev. (Low)
speed Track link speed/
44.0 ± 4.0
3 rev. (High)
Track link speed/

64.0 ± 4.0
Reverse 3 rev. (Low)
speed Track link speed/
44.0 ± 4.0
3 rev. (High)
186
SWING SPEED FOR 3 TURNS
1 Preparation
Fig. 4
2 Measurement
1 Set the swing control lever to full stroke.
2 Measure the time required for three full turns at a
constant speed.
Three full turns
Fig. 5
3 Determination
Unit: sec.
Item Standard
Swing speed/3 rev. R 34 ± 2
Swing speed/3 rev. L 34 ± 2
187
AMOUNT OF SWING COAST
1 Preparation
Fig. 6
1 The arm cylinder should be fully retracted.

2 The bucket cylinder should be fully extended.
3 Place an aligning mark between the swing frame
and the track frame.
4 Swing the superstructure so that the swing frame is
at 180° to the track frame.
2 Measurement
1 Set the swing control lever to full stroke.
2 After swinging 180°, return the lever to the neutral
position.
3 Measure the amount of coast.
Amount of
coasting
Swing stop
180° swing
Fig. 7
3 Determination
Unit: mm (in)
Item Standard
Less than
Loader
Amount of 1 100 (42.9)
coast
(L/R) Less than
Backhoe
1 100 (42.9)
188
CYLINDER SPEEDS (Backhoe front)
1 Action
Boom Cylinder
Fig. 8
Arm Cylinder
Fig. 9
2 Repeat the time measurement at least

3 times for each item and record the
average time.
Bucket Cylinder
Fig. 10
3 Determination
Unit: sec.
Item BE Front BE
7.55 m Boom
Raise 4.6 ± 0.5 3.4 m BE Arm
Boom cylinder
Lower 3.5 ± 0.5 7.0 m3 Bucket
Roll in 4.4 ± 0.5

Arm cylinder
Roll out 4.2 ± 0.5
Roll in 3.2 ± 0.5

Bucket cylinder
Roll out 2.7 ± 0.5
189
AMOUNT OF CYLINDER CREEP
1 Preparation
1 200 mm
(47 in)
Fig. 11
With a full load in the bucket, set the front-end

attachment as shown above.
2 Measurement
Mark Mark
1 Stop the engine.
2 Measure the amount of creep over 5 minutes.
3 Determination
Fig. 12
Unit: mm (in)
Backhoe Front
Item A−B = Creep
BE
Boom cylinder, mm/5min 30 (1.18)
Arm cylinder, mm/5min 30 (1.18)
Bucket cylinder, mm/5min 30 (1.18)
BE
7.55 m Boom
3.4 m BE Arm
7.0 m3 Bucket
Mark
Mark
Apply touch-up paint if necessary.
Fig. 13
190
ADJUSTMENT OF CLEARANCE AT FRONT JOINT
This pages explains how to adjust the clearance at the front
joint. With too large clearance, abnormal noise is produced
when swinging the superstructure. Adjust the clearance by
using shims according to this pages.
1 Outline of Shim Adjustment
Shims at shipment
Applicable Total clearance Requirements for

Points to adjust Part No. Part Name QTY
front No. at shipment inserting a shim
Frame Put the shim outside,

BH Shim (2.3) Machine S/No.
and 4309865 3 1 mm to 9 mm when total clearance is
BE boom ø162 × ø350 1001 and up
boom more than 2.5 mm.
Because the total

Boom
BH Not clearance is adjusted to
and 0.5 mm to 2 mm
BE arm required 2 mm and less, new ones
arm
require no shim.
Because the total

Arm clearances
BE Not
and is adjusted to 2.4 mm
BE arm required
bucket and less, new ones
require no shim.
Frame Put the shim outside

Shim (2.3)
and Boom 4309865 3×2 4 mm to 12 mm when total clearance is
ø162 × ø350
cylinder more than 4 mm
· The shims shall be inserted in such a way that the difference in the quantity of left and right shims can be minimized.
191
2 Points to be Inserted
Backhoe front
Frame Inside Outside
and
Boom
Boom Fig. 1
Backhoe front
Frame
Inside Outside
and
Boom cylinder
Boom cylinder
Fig. 2
192
FORWORD
These completed assembly check sheets are intended for use in

checking whether the machine has been assembled correctly and
completely.
All components requiring field assembly are illustrated in
perspective view, so that even an inexperienced serviceman will
be able to verify the assembly procedure easily.
We recommend that you use these check sheets to check all field
assembled sections.
Building up product quality Maintaining machine quality through

at the field assembly stage correct preventive maintenance
194
Report No. 01
COMPLETED ASSEMBLY CHECK

REPORT FOR THE EX1200-7B
D / M / Y
Inspection date
Country: Machine Serial No.:

Customer name: R
Dealer name: Engine Serial No.: L
Inspected by :
Specifications
Front att. Date of Date of
Front att. Capacity Hour meter
S/No. Inspection Delivery
Boom m D/M/Y D/M/Y
Backhoe front Arm m
Bucket m3 Hours
(Hitachi use) (Hitachi use)
Type of work Mining ( Coal Coal Overburden Gold Other )

Stone Crushing Quarry
Civil Engineering Work Road Building Land Development
Pipelaying Other
Dredging
Other
ANY COMMENTS
195
Report No. 02
EX1200-7B ASSEMBLY CHECK SHEET (1/3)

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
UPPERSTRUCTURE (1/2)
6-2. CONNECTION OF UPPERSTRUCTURE AND SIDE FRAMES

No. Step Page Checking item Mark
1 1 57 Preparation of the side frame assembly (left)
2 2 58 Wire rope handling work of the Upperstructure
3 3 59 Preparation of the track frame
4 4 60 ~ 61 Connecting the upperstructure to the side frame (left)
5 5 62 ~ 63 Connecting the side frame (right) to the track frame
6 6 64 Removing of the wooden blocks
7 7 65 The tightening procedures for the bolts used to attach the track frame are
described below
8 8 66 Retightening of the remaining bolts
6-3. CONNECTION OF TRAVEL MOTOR HOSES

9 1 67 Connection of the travel motor hoses
10 2 68 Installation of covers, ladders and steps
6-4. ASSEMBLY OF CAB & HANDRAIL, STEP AND LADDER ETC.

11 1 70 Backhoe-front cab assembly
12 2 71 ~ 73 Mirrors mounting location & angle
13 3 74 Installation of fenders, step, ladder, etc.
14 4 75 Installation of fenders, handrails and step, etc.
15 5 76 Installation of duct assembly
16 6 77 Removal of a SCR muffler
ANY COMMENTS
196
Report No. 03

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
UPPERSTRUCTURE (2/2)
6-5. INSTALLATION OF COUNTERWEIGHT, SCR MUFFLER, CAMERA AND REAR LAMPS

17 1 79 ~ 80 Installation of the counterweight
18 2 81 Installation drain off hose
19 3 82 ~ 86 Installation exhaust pipe
20 4 87 Installation of the camera ass'y and rear lamp ass'y
21 5 88 Installation aerial angle (1)
22 6 89 Installation aerial angle camera
25 9 92 ~ 93 Installation aerial angle (4)
6-6. GREASING OF SWING BEARING

26 — 95 ~ 97 Greasing (1)
6-7. VACUUMING (AIR PURGE WORK) & CHARGING OF REFRIGERANT

27 — 118 (99 ~ 117) Cooler installation check sheet
6-8. FINAL CHECK OF SUPERSTRUCTURE

28 1-1 119 Check the coolant levels in the radiator
29 1-2 119 Check the oil levels in reduction gears for swing reduction devices
30 1-3 119 Check the oil level in the engine oil pan
31 1-4 119 Check the oil levels in the final drives (both sides)
32 1-5 120 Check the fuel level in the fuel tank
33 1-6 120 Check the urea and in the urea tank
34 1-7 121 Check the pump transmission oil level
35 1-8 121 Check the hydraulic oil level in the hydraulic tank
36 2 122 Check the batttery
37 2 122 Check the liquid level of battery
6-9. RELEASING AIR FROM MAIN PUMPS

38 — 123 Releasing air from main pumps
6-10. TRIAL OPERATION OF SUPERSTRUCTURE

39 — 125 Trial operation of superstructure
ANY COMMENTS
197
Report No. 04

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
BACKHOE FRONT (1/1)
7-1. PREPARATION
1 2 132 ~ 136 Preparation of the boom
2 3 137 ~ 138 Preparation of the arm
3 4 139 Preparation of the bucket
7-2. MOUNTING OF BACKHOE BOOM

4 1 141 ~ 142 Mounting the boom
5 2 143 Connection of the hoses to basic machine and boom
6 3 144 ~ 146 Installation of the boom cylinders
7 4 147 ~ 148 Greasing (2)
8 5 149 ~ 150 Air bleeding of the boom and arm cylinders
7-3. MOUNTING OF ARM

9 1 151 ~ 155 Installation of the arm
10 2 156 ~ 157 Greasing (3)
11 3 158 ~ 159 Air bleeding of the arm and bucket cylinders
7-4. MOUNTING OF BUCKET

12 1 161 ~ 165 Mounting of the bucket
13 2 166 ~ 167 Greasing (4)
14 3 168 Air bleeding of cylinders
15 4 169 Bleeding locations
7-5. ADJUSTMENT OF TRACK LINK TENSION

16 — 171 Adjustment of track link tension
7-6. FINAL TRIAL OPERATION CHECK

17 — 173 Final trial operation check
ANY COMMENTS
198
Report No. 05
SATISFACTORY
IMPLEMENT SPEEDS
UNSATISFACTORY
CORRECTED
Inspected by:
The figures and tolerances listed below are for new machines.
For machines already in operation, a certain allowance is
permitted according to working conditions and the hourmeter
reading on the machine.
The measurements should be performed under the following
conditions:
1. TEST CONDITIONS
Item Condition Test Result

Road Surface Level
Hydraulic Oil Temperature 50°C ± 5°C (122°F ± 41°F) °C (°F )
Low idling 850 ± 50
Auto idling 1400 ± 50
ECO mode
High idling 1700 ± 50
Engine Speed (rpm) PWR mode
HP mode
(ECO Control Suspend)
199
Report No. 06
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
2. TRACK LINE SPEED/3 TURNS
Unit: sec.
Working Time
Item Criterion Evaluation
1 2 3 Avg.
TRACK LINK
64.0 ± 4.0
SPEED/3 rev. (Low)
Forward
TRACK LINK
44.0 ± 4.0
SPEED/3 rev. (High)
R
TRACK LINK
64.0 ± 4.0
SPEED/3 rev. (Low)
Backward
TRACK LINK
44.0 ± 4.0
SPEED/3 rev. (High)
Travel
TRACK LINK
64.0 ± 4.0
SPEED/3 rev. (Low)
Forward
TRACK LINK
44.0 ± 4.0
SPEED/3 rev. (High)
L
TRACK LINK
64.0 ± 4.0
SPEED/3 rev. (Low)
Backward
TRACK LINK
44.0 ± 4.0
SPEED/3 rev. (High)
200
Report No. 07
SATISFACTORY
UNSATISFACTORY
CORRECTED
3. SWING SPEED/3 TURNS
Inspected by:
Three full turns
Unit: sec.
Working Time
1 2 3 Avg.
R 34 ± 2
Swing Speed/3 turns
L 34 ± 2
4. AMOUNT OF COAST WHEN SWINGING
Amount of
coast
Swing stop Swing start
180° swing
Unit: mm (in)
Coasting Amount
1 2 3 Avg.
Less than
R 1100 (42.9)
Amount of Coast
Less than
L 1100 (42.9)
201
Report No. 08
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
6. CYLINDER SPEEDS (Backhoe front)
Unit: sec.
Criterion Working Time
Evaluation
BE 1 2 3 Avg.
Raise
Raise 4.6 ± 0.5
Lower
Lower 3.5 ± 0.5
Roll-in 4.4 ± 0.5
Roll-out 4.2 ± 0.5

Arm Roll-out Arm Roll-in
Bucket Roll-in 3.2 ± 0.5

Roll-out
Bucket
Roll-in Roll-out 2.7 ± 0.5
ANY COMMENTS
202
Report No. 09
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7. DEGREE OF CYLINDER CREEP (Backhoe front)
1 200 mm
(47 in)
Unit: mm (in)
Criterion Measured Data
Item Evaluation
BE 1 2 3 Avg.
Boom Cylinder
30 (1.18)
mm/5 min
Arm Cylinder
30 (1.18)
mm/5 min
Bucket Cylinder
30 (1.18)
mm/5 min
203
NOTES
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................... ............. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . .. . . . . . . . . ............................... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .......................................................................................... .. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .................................................................... ........................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .............................................. .............................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ........................ ....... ............................................................. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ............................................................................................ . . . . . . . . .
204

Ex1200 7b Ko 590 01 Assembly Manual

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Ex1200 7b Ko 590 01 Assembly Manual

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KO-590-01

Bucket Bucket cylinder

Track spring Counterweight

1 RECOGNIZE SAFETY INFORMATION

Follow recommended precautions and safe operating

2 UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous situation

WARNING indicates a potentially hazardous situation

CAUTION indicates a potentially hazardous situation

The NOTE describes cautionary remarks, reference,

DANGER and WARNING safety signs are located near

To avoid confusing machine protection with personal

Safety signs should be installed, maintained, and

Learn how to operate the machine and its controls

Keep your machine in proper working condition.

The safety messages in this chapter are intended to

4 DESIGNATE ONE LEADER AND TWO

5 CLEAN THE MACHINE REGULARLY

Do not spray water or steam inside the cab.

Wear close fitting clothing and safety equipment

You may need:

7 PREPARE FOR EMERGENCIES

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

8 PREPARE SUITABLE LIFTING TOOLS

10 SUPPORT RAISED BUCKET

Falling is one of the major causes of personal injury.

Never jump on or off the machine. Never mount or

Be careful of slippery conditions on platforms, steps, Fig. 1-11

13 PREVENT BATTERY EXPLOSIONS

Never check the battery charge by placing a metal

Do not charge a frozen battery - it may explode. Warm

Disconnect the negative ground cable before working

• Avoid this hazard by relieving pressure before

• Search for leaks with a piece of cardboard, taking

• If an accident occurs, see a doctor familiar with this Fig. 1-14-1

Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4

15 CHECK EQUIPMENT SAFETY

Wear a suitable hearing protective device such as

17 FASTEN YOUR SEAT BELT

Be sure to remain seated with seat belt securely

18 BEWARE OF EXHAUST FUMES

If you must operate in a building, be sure there is

Never lubricate or service the machine while it is

Before servicing the machine.

• Park the machine on a level surface.

If a maintenance procedure must be performed with the

Inspect certain parts periodically, and repair or replace 90 to

Disconnect the battery ground cable (-) before making

Before performing any work on the machine, attach a

21 REMOVE PAINT BEFORE WELDING OR

Avoid potentially toxic fumes and dust.

Do all such work outside or in a well-ventilated area.

Remove paint before welding or heating:

1 If you sand or grind paint, avoid breathing the dust.

2 If you use solvent or paint stripper, remove stripper

22 PROTECT AGAINST FLYING DEBRIS

In order to avoid personal injury, keep bystanders away

Hot fluids and surfaces:

25 STORE ATTACHMENTS SAFELY

Securely store attachments and implements to prevent

Use leakproof containers when draining fluids. Do not

Allowing air conditioning refrigerants to escape into the

Inquire as to the proper way to recycle or dispose of