OPERATION MANUAL EX2<00 EX200LC Hydraulic Excavator ©@ HITACHIMACHINE Mfg. No. ENGINE TYPE ENGINE Mfg. No. REMARKS.TO THE READER This manual is designed to serve as a reference for HITACHI customers and distributors who wish to gain basic product knowledge on Hitachi EX200/EX200LC Hydraulic Excavator. To maintain it in optimum condition and retain maximum performance over a long period of time, CORRECT OPERATION and PROPER MAINTENANCE are essential. PART ONE describes the operation procedures, PART TWO details the inspection and main- tenance, and PART THREE covers handling optional attachments. Please read through this manual, and utilize it to attain the maximum performance. The descriptions in this manual may be subject to changes without prior notice. READ SAFETY REGULATIONS CAREFULLY AND UNDERSTAND THEM BEFORE US- ING YOUR EXCAVATORCONTENTS PART ONE: TO THE OPERATOR and dealer's service personnel . .. SAFETY ........ ceeteeee CONTROLS AND INSTRUMENT . PRESTART INSPECTION OPERATION ......... ce BASIC MACHINE OPERATION ...... TRANSPORTING .......-.0..055 PART TWO: TO THE MECHANIC and dealer's service personnel... . 45 SAFETY . fees teeters ences 47 COMPONENTS LOCATIONS AND CIRCUITS 53 GENERAL .......... HYDRAULIC SYSTEM ELECTRICAL CIRCUIT... MAINTENANCE . MAINTENANCE GUIDE A. GREASING B. ENGINE OIL C. GEAR OIL D. HYDRAULIC SYSTEM E. FUEL SYSTEM F G. H. AIR INTAKE COOLING SYSTEM |. ELECTRICAL SYSTEM 93 |. OTHERS 95 MAINTENANCE SERVICES UNDER VARIOUS CONDITIONS « + 104 STORAGE ceeeeee : cesses 105 ASSEMBLY OF FRONT-END ATTACHMENT «20... ccsccese0: cevceeeeees 107 TROUBLE SHOOTING . cece : cette 119 SPECIFICATIONS 129 PART THREE: HANDLING OPTIONAL ATTACHMENTS «-..-.. 2-52-0020 02005 133TO THE OPERATOR and dealer's service personnel Read this manual carefully to learn how to operate and service your excavator correctly. WARRANTY The warranty on this excavator appears on your copy of the purchase order which you should have received from your dealer when ‘making your purchase. This warranty provides you the assurance that HITACHI will back its products where defects caused by faulty work. manship appear within the warranty period. In some circumstances, HITACHI also provides field improvements, often without charge to the customer, even if the product is out of war- ranty. Warranty and field improvements are a part of HITACH’s product support program for cus- tomers who operate and maintain their equ ment as described in this manual. Should the equipment be abused, or modified to change its performance beyond the original factory speci fications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise ‘overpowering machines will result in such action. Due to subsequent improvements, the specifi- cations of your machine may be partially dif- ferent from the descriptions of this manual. DIRECTIONS Left, right, front, and rear in this manual are seen from the operator's seat facing forward, propel motors at the rear. MEASUREMENTS SI units equivalent and conventional metric system in parenthesis are used in this manual. MACHINE NUMBERS Write your machine serial number and engine number shown below as well as machine model and engine type. Your dealer needs this in: formation when you order parts and/or when- ‘ever you contact them, Machine model _EX200/EX200LC Serial No. Engine type 1sUZU-6BD1 (T) Engine Serial No. In this manual, SDX and DX are mentioned on some headings, As supplied machines are different subject to territory and/or machine, please confirm which one is applicable.Safety 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 operating practices, UNDERSTAND SIGNAL WORDS A signal word— DANGER, WARNING, or CAUTION —is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARN- ING are typically near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety mes- sages in this manual. FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your machine safety signs. Follow recom: mended precautions and safe operating practices. Keep safety signs in good condition. Replace mis- sing or damaged safety signs. Awarninc AcautionSafety A CAUTION UNDERSTAND MACHINE OPERATION Only qualified people should operate the machine. Learn the location and purpose of all controls, struments, indicator lamps, and caution plates. A CAUTION WEAR PROTECTIVE CLOTHING Wear fairly tight clothing ... and safety equipment. A CAUTION USE SAFETY EQUIPMENT Fasten a first-aid kit and a fire extinguisher to the machine. Keep the extinguisher fully charged. Learn to use it correctly. A CAUTION INSPECT EXCAVATOR Inspect your excavator carefully each day before you start it. Use the check list on page 29. Do not start or operate the excavator unless you are in the operator's seat. When you operate the excavator, do not let another person on the machine. When you get on or off the excavator, use hand rails and steps. Start the engine only in well-ventilated area. Before you move the boom or arm, be sure all per- sons are away from the excavator. —4.Safety A CAUTION PRECAUTIONS FOR INSPECTION AND MAINTENANCE Be sure to stop the engine. Place a notice board “under inspection and mainte- nance” on the cab door or control lever. Never get under the machine while it is jacked up by the boom and arm: When inspecting or servicing the machine with raised boom and arm, always use safety blocks, safety supports, etc. A CAUTION MOVE EXCAVATOR SAFELY Before you move the excavator, find out which way to move propel pedals for the direction you want to go. If propel motors (A) are in front of the cab, push down the rear of the propel pedals (B) to move forward. Do not travel without a signal person for a guide. Do not travel near the edge of a ditch, gully, or ex- cavation. Travel carefully where room is limited, over rough ground, and on slopes. A CAUTION PARK SAFELY Before you leave the cab: Lower bucket to ground. Stop engine. Put control lever in neutral position. If you park the excavator on a slope, put blocks against tracks. Do not park excavator with tracks pointed down- hill, Take the engine key and cab door key with you.GETTING IN/OUT THE MACHINE Foot steps and hand rails are provided at various places. These are to ensure safe checking and maintenance, and to get in or out the machine safely, CAUTION Do not jump in or jump out the machine. It is dangerous. Do not fasten slings to these foot steps or hand rails to lift the cab or the basic machine, or to stabilize the machine during transportation on a truck or trailer.Controls and Instruments CONTROLS @® Swing and Arm Control Lever CAUTION: See page 23 Left Propet Lever © Right Propel Lever © Boom and Bucket Control Lever A caution: s page 23 © Control Neutralizer Lever This machine is equipped with @ contro! neutra- lizer lever. It is located on the left side of the operator's seat When you are sitting on the seat (with the control neutralizer lever lock release position) A CAUTION LOCK POSITION When you get off the machine (Pull the contro! neutra- lizer lever © to lock position) All actuators will not move if a control lever is oper- ated by error.Controls and Instruments INSTRUMENT PANEL (SDX) ® Accelerator Lever Starter Switch Cigarette Lighter Monitor Panel Heater Switch Radio Fuse Box Heater Cock Lever ©©O0®O0@®O 2-Speed Travel Switch © Wiper Switch @® Mode Selection Switch © Lighting Switch @® Auto Idling Switch © Buzzer Stop Switch ® Door Lock Release Lever @ Horn Button ® Preoperation Check SwitchControls and Instruments INSTRUMENT PANEL (DX) © Accelerator Lever © Starter Switch ® Cigarette Lighter © Monitor Panel © Fuse Box © Wiper Switch © Lighting Switch © Buzzer stop Switch ® Door Lock Release Lever © Horn Burton —10~Controls and Instruments ACCELERATOR LEVER (F) (SDX) It adjusts the engine speed (output) and also serves as a stop engine. The lever is normally braked. Before operating the lever, never fail to press the button on the grip for releasing the brake. ® Engine stop: The lever is fully pushed foreward. (Caution) Do not take your hand off until the engine has stopped completely. If you take off your hand, the lever will reset close to the low idling position automatically. @® Low idling: Pull the lever a little backward, and push it again foreward to a point where the lever control becomes heavy. @® High idling: Pull the lever fully backward from the low idling position IMPORTANT If auto idle switch is set to the ON position, or mode switch is in either L or E position, fuel lever cannot be operated in accelerating direction. Always set the auto idle switch in the OFF, and the mode switch in the P position before moving the operation lever. =Controls and Instruments ACCELERATOR LEVER ® (DX) To ensure an optimum engine rpm for particular work and to reduce fuel consumption, a panel with Economy Range is provided for the Accelerator Lever. The lever is normally braked. Before operating the lever, never fail to press the button on the grip for releasing the brake. Each range indicates as follows He Full Range (Red range) E: Economy Range (Orange range) Economy Range’s engine rpm is 70 to 85% of the Full range’s rpm. L: Low Speed Range (Yellow range) STOP: Engine Stop Range Choose one of these ranges for each particular work. Especially, when the Economy Range is used, although it depends on the work condition, the fuel consumption is reduced approx. 20 to 35%. Choose suitable range for each work. By choosing a suitable range for the work, setting the engine rpm for the work thereafter is made easy. The working speed is reduced accordingly to the range chosen compared to the Full Range. =12~Controls and Instruments STARTER SWITCH @) Go @ @ Switch OFF Preheat Starter ON ‘Switch ON (Operating) GAUGES AND INDICATORS (SDX) in the Monitor Panel (1) a 2 13) a 18 16 7 48 Clock Engine Coolant Temperature Gauge Fuel Gauge Service Meter Charge Lamp Engine Oil Pressure Warning Lamp, Engine Oil Filter Clog Warning Lamp Air Cleaner Filter Clog Warning Lamp Overheat Warning Lamp Fuel Level Warning Lamp Preheat Timer Pilot Lamp Head Light Pilot Lamp Engine Oil Level OK Lamp Engine Coolant Level OK Lamp Hydraulic Oil Tank Level OK Lamp Auto-Idling Pilot Lamp Low-Speed Travel Pilot Lamp High-Speed Travel Pilot Lamp Preoperation Check Switch Buzzer Stop Switch 13—Controls and Instruments GAUGES AND INDICATORS (DX) in the Monitor Panel (1) Engine Coolant Temperature Gauge Fuel Gauge Service Meter Charge Lamp Engine Oil Pressure Warning Lamp Air Cleaner Filter Clog Warning Lamp Overheat Warning Lamp Preheat Timer Pilot Lamp Head Light Pilot Lamp Buzzer Stop Switch =14-Controls and Instruments This Monitor Panel consists of the following three categories: (1) Indicators which show the present machine condition by analogue system. (2) Green lamps which show sufficient fluid levels. (3) Warning lamps which are in red in case of abnormality. FUNCTION OF EACH GAUGE AND INDICATOR @® Engine Coolant Temperature Gauge ‘© Green zone indicates normal operating temperature. © After the engine started, keep low idling until the needle comes into green zone. @® Fuel Gauge —ruee BS © When the needle reached “€”, the fuel tank.is almost empty. Supply fuel immediately, @ Service Meter © The first digit (right end) indicates 0.1 hour (6 minutes). service merer 54 (S) To set the hour and minutes of the swtich * Pushthe X , Y switch to set hour and minutes: X switch sets minutes (look down at left switch) Y switch sets hour (look down at right switch) —15~Controls and Instruments SDX) By pressing the preoperation check switch (V) before starting the machine, the green lamps 43 , (@ and @ turn ON if the respective liquid levels are normal, In case of abnormality, the respective red warning lamps ®&,®,@®,@,@ and/or 40 turn ON. When @® and @ are abnormal, the buzzer sounds at the same time. If @ is abnormal, the buzzer sound is stopped by pres sing the buzzer switch (8), By taking off your hand from the switch, the buzzer function will be automatically recorvered, making the buzzer sound in case of another abnormality. When the fuel level warning lamp turned ON on a level ground, it indicates the remaining fuel is about 43°. In this case, supply fuel as soon as possible. cca) When you switch on the Lighting Switch ©, the Lamp 42 and monitor interior lamp will be lit in green. First Stage! Right hand head lamp only. Second Stage: Boom head lamp also. oFF 16—Controls and Instruments (DX) In case of abnormality, the respective red warning lamps ®. ©, ®, and/or ® turn ON. When @) and @) are abnormal, the buzzer sounds at the same time. tf © is abnormal, the buzzer sound is stopped by pres sing the buzzer switch (8), By taking off your hand from the switch, the buzzer function will be automatically récorvered, making the buzzer sound in case of another abnormality. HEAD LIGHT When you switch on the Lighting Switch @) , the Lamp will be lit in green. First Stage: Right hand head lamp only. Second Stage: Boom head lamp also, aControls and Instruments LAMP BULB CHECK By turning ON the starter switch, the OK lamps @), © and @& (SDX only) and the warning lamps turn on for about 2 seconds. Any lamp that fails to turn on needs replacement of its bulb. These lamps also turn on for about 2 seconds by turning the starter switch to PREHEAT or START, which is not abnormal. sve, (sDx) IMPORTANT (1) This monitor system is only to give you an indication of machine conditions. To ensure machine conditions, regular visual checks and maintenance of fluid levels etc. should be per- formed. (2) The front cover of the indicators (parts name: panel gauge), made of formed resin, should be cleaned with a wet cloth. A dry cloth must not be used as it may damage the cover. —18~Controls and Instruments MODE SELECTION (SDX only) 3 operation modes can be selected by operating the mode selection switch located on the right console, In each of these operation modes, a microcomputer selects automatically the best combination of the engine speed and the flow rate of the pump which fits the current working conditions and purpose. Use the following table for making the best choice to improve the working efficiency. P (Power) Mode : For high speeds and large work volumes. E (Economy) Mode The work volume will be slightly lowered from P Mode, but it im proves fuel efficiency greatly and reduces noise level L (Light) Mode For low speeds to obtain high precision. The engine speed is further lowered, allowing more improved fuel consumption and noise level. The digging power is the same as in P and E Modes. Mode Selection Criteria (SDX only) Selection Points Examples of Work For handling many works in a short time. When many dump trucks are waiting for loading. Work volume Digging and dumping works. Digging and loading earth and sand. Heavy duty digging igh speed travelling General works. For improving working efficiency and fuel consumption rate. For reducing noise. ney Digging and loading earth and sand. Preparing agricultral land. Levelling ground, Moving in site When working at low speed to improve precision. To further reduce noise, When fuel consumption is more weighted than working speed. Precision GOEHOH C/OOO O/O© CO High precision works such as normal cutting and levelling Works in limited spaces. Lifting works using soil supports. Night works in urban areas. Moving in small sites. Carrying unhardened concrete. Getting out of fragile lands. -19-Controls and Instruments SELECTION OF HIGH-SPEED AND. LOW-SPEED TRAVEL (SDX only) Either high-speed or low-speed travel can be selected in each working mode by changing over the high/low speed selection swtich provided on the right console. When you wish to lower the travel speed, such as in travelling on a tilted ground or moving in a limited space, the travel speed can be adjusted simply by chang- ing over this switch, IMPORTANT In this system, a microcomputer automatically selects the best combination of the engine speed and the flow rate of the pump according to the position of the selec: tion switch and the current operation. Therefore, the engine speed is changed by a lever control or switch selection, which should not be regarded as abnormal. —20~Controls and Instruments AUTO IDLING DEVICE (SDX only) This machine is equipped with Auto Idling Device which automatically reduces the engine rpm when control levers are put in the neutral position. Turning ON/OFF of this auto idling device can be done by the auto idling switch (A) easily # When auto idling is activated Engine rpm increases when each control levers are operated up to the level controled by the fuel lever Four seconds after the control levers are returned to the neutral, the engine rpm is reduced automatically to the level set by the auto idling device. ‘* When auto idling is turned “OFF The engine rpm can be controled by the fuel lever at your will IMPORTANT Auto idling device does not work if the engine speed set by the accelerator lever is lower than the engine speed set by the auto idling device. PRECAUTIONS BEFORE OPERATION (1) Always check ON/OFF of auto idling device before operating any control levers (2) When auto idling device is activated, even if the engine rpm set by the fuel lever is at high speed range; the engine rpm would be reduced to the engine rpm set by the auto idling device drastically if the control levers are put to the neutral position, and increased drastically when control lever(s) is, operated, If auto idle switch is set to the ON position, or mode switch is either L or E position, fuel lever cannot be operated in accelerating direction. Always set the auto idle switch in the OFF, and the mode switch in the P position before moving the operation lever. Acaution When loading/unloading the machine to or from the trailer, always turn “OFF” the auto idling switch for your safety. Travel speed is increased abruptly and therefore directional operation can not be carried out freely, which may result in serious accident like tum! and overturn. (3) -21-Controls and Instruments PROPEL LEVERS (OR PEDALS) Ar caurron: sake sure you know the location and function each control and sound the horn to alert the people nearby before operating. A caumon: rior to travelling, make certai the Propel motor is at the rear side observing from ‘the advancing direction. When travelling with the propel motor turned to the front side, note that the operating direction of the Propel lever is reversed. This machine is equipped with both Propel Levers and Pedals. Here we explain the Pedal operation. (1) Push down the front of both pedals (A) and ©) to travel in forward. (2) Push down the rear of both pedals ((8) and ©) to travel in reverse. {@) Right Turn: Push down front of left pedal @. (4) Left Turn: Push down front of right pedal ©. (8) Neutral position ©: Parking brakes will be on to hold the excavator. (6) Spin Turn (Counter rotate): Push down the front of ‘one pedal and the rear of the other. ®— Left Track Forward @— Left Track Backward ©— Right Track Forward ©— Right Track Backward ©— Neutral Propel Motor Propel lever dampers This machine is provided with propel lever dampers to allow smooth propel controls. In an extremely cold weather (less than -20°C), the propel lever (pedal) control may get heavy, which is due to the damper effect and not an abnormality. In such case, when running the machine for warm-up, operate the propel levers (pedals) forward and backward several times, with the control neutralizer lever kept turned OFF. 22Controls and Instruments SWING AND ARM CONTROL LEVER A CAUTION: Make sure you know the location and function each control before operating. The control pattern shown is HITACHI standard, and the pattern is changed depending on country. Note: With this control pattern, functions must corres: pond to the label located on cab wall When you release the lever, it will return to neutral, The Swing and Arm will stay in position, ® — Swing Right @— Swing Lett @©- Arm Extend ©~ Arm Retract BOOM AND BUCKET CONTROL LEVER caution: Make sure you know the location and function each control before operating. The control pattern shown is HITACHI standard, and the pattern is changed depending on country. Note: With this contro! pattern, functions must corres: pond to the label located on cab wall. When you release the lever, it will return to neutral, Boom and Bucket will stay in position @®- Boom Lower @®~— Boom Raise ©- Bucket Crowd © - Bucket Dump A caution: Control directions of the levers shown this page is based on the standard EX200 or EX200LC, Confirm by yourself the instruction on the plate attached to the cab wall. ~23~Controls and Instruments ADJUSTING CONTROL LEVERS The swing/arm lever and the boom/bucket lever can be adjusted by tilting them back and forth. Insert a bar wrench (10 mm width across flats) into the adjustment hole @). loosen the inside socket bolt, and pull the grip (back or forth) for adjustment. The adjustment range is 70 mm forward and 30 mm backward. Tightening torque: 88 N-m (9 kgf-m) caution Before adjusting the control levers, be sure to place the bucket onto the ground and stop the engine. ~24—Controls and Instruments OPERATOR SEAT ADJUSTMENT (1) Height adjustment 1) Loosen the lock handle. (Turn it anticlockwise) (2) Pull up the height adjusting lever. (If it is hard to pull up the lever, try to shake the seat up and down.) The seat can be adjusted in 5 positions at 20mm intervals. (3) Move the seat to the height desired, and take your hand off the lever. At that time, check that a lock pin is securely applied to the notch. 4) Turn the lock handle clockwise to lock the seat stand (2) Reclining Adjust it by pulling the reclining lever located on the left and rear side of the seat. The reclining angle can be adjusted at 4 points for: ward and 16 points backward at 3° intervals. Also, fully pushing down forward, about 49° can be made, (3) Slide Make it by controlling the adjusting lever shown above. There are 7 adjusting points at 20 mm intervals (140 mm in total), If further adjustment is required, remove the stand: fixing bolts (4 bolts), and additional 40 mm or 80mm can be adjusted. After shifting the stand, adjust the position of the seat again by the adjustment lever. (4) Arm-rest The arm-rest can be tilted up and stored 180° rear ward. (5) Head-rest The height can be adjusted at one point. Adjust it as, required, ‘Adjusting lever (sliding) ~25—Controls and Instruments OPENING AND STORING FRONT UPPER WINDOW (1) Full closing position, Press the window pane forward, and fix it firmly by (sliding) the right and left lock pins. (2) Full opening position (storing) Slide up the front glass overhead along with the both side groove rails. When the front window js raised, first confirm the autolock is effective, and fix it by the right and left lock pins. NOTICE Before the front glass is opened or close, be sure to disconnect the connector for the wiper. —26~Controls and Instruments FIXING AND REMOVING FRONT LOWER WINDOW (1) Fixed position Fix it firmly by the right and left lock pins. (2) Removed and Stored position Insert the pin below the window pane into the bracket hole (A), and fix it firmly with the bracket (B) by the right and left lock pins. Door Lock (1) Releasing the lock to open the door. Pull Down the lever. —27-Controls and Instruments CAB HEATER (SDX only) When using the heater, open the hot water cock for the engine heater to set the heater dampers in H and HEAT positions respectively. Use the heater switch Q)and heater cock @) to adjust the temperature in the cab, In the season when the heater is not needed, close the cock for the heater of the engine to ensure that the hot water does not come to the heater. Weak Normal strong ; thot! ot! dD me Alt Hi position Damper postion An air conditioner is optionally available. Contact your service station BREAK-IN A NEW MACHINE Each new machine is thoroughly inspected and adjusted at factory. However, please perform break-in operation as explained in the table below. Hours (By hourmeter) Load Initial 50 hours 80% of full load After this 60 hours Full load Applying full load without break-in operation causes seizure and/or scratches, and consequently affects the service life of the machine and safe operation. ——_! BREAK-IN THE EXCAVATOR CORRECTLY During thé first 50 hours of operation: (1) Check coolant level, engine oil level, and hydraulic reservoir oil level regularly. Watch for leaks. Use only specified lubricants and coolant. (2) Service lubrication points regularly. (3) Tighten accessible hardware regularly, (4) Check gauges and indicators often during operation. (5) Warm-up excavator carefully, then operate at normal loads. (6) Be alert to the special sounds and feel of your excavator, —28~a PRE START INSPECTION INSPECT EXCAVATOR DAILY BEFORE STARTING Front attachment Arm, Bucket Hydraulic oil tan {with a built-in full flow filter) Undercarriagi NN Track folter! Carrier roller ~ OS Sipeesructue \ MN Battery N\ swing unit (motor, reduction gears parking brake) Control valve Fuel tank Counterweight Engine Muffler Pump Air cleaner] Proped unit NN (Motor, reduction gears, parking brake) FIRE EXTINGUISHER Check charge. ELECTRICAL SYSTEM Check for worn or frayed wires and loose con: nections, BOOM, BUCKET, SHEET METAL, TRACKS Check for bent, broken or missing parts. HARDWARE Check for loose or missing parts. HYDRAULIC SYSTEM Check for leaks, kinked hoses, and lines or hoses that rub against each other or other parts. LUBRICATION Check lubrication points on Periodic Service Chart, PROTECTIVE DEVICES Check guards, fenders. ~29~OPERATION STARTING THE ENGINE (1) Make sure that each control levers are at the neutral position. (3) Turn the starter switch to the “ON” position. (4) Activate the starter by turning the starter switch. Start ON OFF (5) Immediately after the engine starts, release your — hand from the switch. | @ “I Start ON OFF | (6) Return the fuel lever to the low idling position, A caunion Before starting the engine, sound the horn to alert the people nearby. IMPORTANT (1) Do not crank engine by starting motor longer than 15 seconds. Wait 2 minutes before you try again, (2) Observe the item (5) or the starter may be damaged. (3) Keep the starter switch at "ON" position during operation. Turning the switch to "OFF" causes damage on its electrical circuit. (4) When the engine is idling, the vibration of the machine may increase due to reasonance. Increase the engine speed slightly to decrease such vibration, (6) If auto idle switch is set to the ON position, or mode switch is either (©) or © position, fuel lev- er cannot be operated in accelerating direction. Always set the auto idle switch in the OFF, and the mode switch in the ®) position before moving the operation lever. (SDX only) 31Operation STARTING PROCEDURE IN COLD CONDITIONS With the accelerator lever in the “OFF” position, turn the starter switch to ON’ position, Crank the engine by the starter for several seconds to make a lubrication film on the hydraulic pumps before the engine starts Preheating (1) Turn the starter switch key to "PREHEAT", and confirm the preheat lamp turns ON, In about 20 seconds, the preheat lamp turns OFF, indicating that preheating has finished When the preheat lamp has turned OFF, start the engine according to "STARTING THE ENGINE” in the previous section. Starter ON Preheat r\ OFF PreheatOperation CHECK INSTRUMENTS AFTER STARTING IMPORTANT: If a gauge does not operate as shown below, IMMEDIATELY STOP THE ENGINE. Find and correct the cause. Check indication of gauges. (1) Engine coolant temperature gauge @) is in the green range (2) Are the warning lamps ©), ( ® and @ OFF? (3) The engine noise and exhaust gas color are normal. ) » @ (SOX only), (SDx) STOPPING THE ENGINE (1) Return the accelerator lever to low position for 5 minutes. IMPORTANT Especially in the case of an engine with a turbo charg- er, stopping the engine suddenly makes the lubricated points of the charger body very hot, which dries up the lubricant and causes failure. (2) Push the accelerator lever fully to stop the engine. (3) Put the starter switch in “OFF” position NOTICE (1) The stopping sequence (2) , (3) above should be in this order, otherwise, troubles in elec trical system may be caused (2) Even if you find a few differences between this manual and “Operation manual of Isuzu 6801(T) Diesel Engine”, please follow the information in this manual —33-Operation ][- WARMING EXCAVATOR NORMALLY (1) Run engine at medium speed for § minutes. (2) Do not run engine at fast or slow idle. (3) Operate excavator at less-than-normal loads and speeds for first 5 to 10 minutes, or until tempera- tures reach normal operating ranges. WARMING EXCAVATOR DURING COLD CONDITIONS A CAUTION If hydraulic oil is cold, hydraulic functions move slow- ly. Never fail to perform the warming-up operation because it is necessary not only for preventing the hydraulic equipment from being damaged but also for safety’s sake. Do not attempt normal excavation op- eration until hydraulic functions move at close-to- normal cycle times. (1) Run the engine at idling speed for more than 5 minutes. (2) Run the engine at half speed for 5 minutes. (3) At that time, do not run the engine at fast or slow idle. (4) Extend the bucket cylinder to the stroke end. (5) Hold bucket control lever all the way left for no more than 30 seconds (6) Retract bucket cylinder to the other stroke end. (7) Hold control lever all the way right for no more than 30 seconds. (8) Continue to repeat steps (4) , (5), (6) and (7) until bucket cycle time is normal. If air temperature is very low, extend the running time of engine at a half speed for warming it up. 34A BASIC MACHINE OPERATION Accaution MOVE EXCAVATOR SAFELY Make sure that the machine is always on firm ground, especially when working close to an edge. At sich times, the machine should be positioned with the propelling motors at the rear as shown. A CAUTION CARRY BUCKET LOW Carry the bucket low at all times, especially when you work on a hillside or propel. Carry the bucket high enough to clear obstacles. Do not let anyone ride in the bucket, CAUTION AVOID TIPPING When you operate on a slope, do not swing the bucket downhill if possible. When you swing heavy loads to the side of the tracks, avoid tipping the excavator. When the bucket is loaded, be careful when you swing or lift the boom, A caution OPERATE WITH CAUTION When you operate, move or haul the excavator, avoid contact between boom or arm and overhead obstacles. Before you dig, check the location of cables, gas lines, and water mains. Do not dig under the machine. If engine stops during operation on a hillside, lower the bucket to ground, Start engine immediately. —35~Basic Machine Operation A caution AVOID POWER LINES. Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to. electric line than 3m (10ft) plus twice the line insula- tor length. A CAUTION CHECK WORKSITE Make sure that the worksite footing has sufficient strength to firmly support the machine. OPERATING IN WATER OR MUD If a river bed is flat and the stream is slow-running the machine can travel in water up to 770 mm deep (up to the upper edge of the carrier roller), If a river bed is uneven and/or the stream is fast-flowing, water depth should be taken into consideration. In the event that the swing bearing and/or center joint are submerged in water or mud, contact your local Hitachi dealer. If the machine is used after being sub- ‘merged, these parts will wear prematurely, 770mm ~36—Basic Machine Operation AVOID HARD DIGGING Do not propel the machine with the bucket thrust into the ground or dig by using the machine’s weight. These operations apply excessive force to the machine, JACK UP OPERATION When jacking up the machine by front attachment as shown, make sure to keep the angle between boom and arm 90°~110" putting the bucket's round face side on to the ground to prevent deformation and shorter life due to unreasonable force at the frontend. AVOID HAMMER WORK Do not use the bucket as hammer or pile driver. Such ‘operation will damage the bucket and other front at tachment parts. -37-Basic Machine Operation a [vor HARD SWING OPERATION Do not shift rocks, attempt to break walls etc., using swing motion. Such operation will damage the front attachment. A CAUTION SPECIAL ATTENTION FOR CRANE USE When you use the machine for crane operation, con- tact your Hitachi dealer to get safe information of lift- ing capacity. L BACKHOE OPERATION © Use the arm cylinder as the main force for digging, © When soil sticks on the bucket, move the arm lever or bucket lever back and forth 2 or 3 times to remove it. @ When lowering the boom, do so as smoothly as possible, to prevent shock loads to the machine. © When operating the arm cylinder, make sure to pro: vide some stroke reserve. © Avoid digging diagonally to the track frame, as the tooth end may hit the track link © For deep excavation, be careful so as not to strike the boom sides or the bucket cylinder hose against the ground,FACE SHOVEL OPERATION (WITH REVERSED HOE BUCKET) With the bucket reversed, the machine can be used as a face shovel. —HOW TO REVERSE — (1) Rest the bucket on firm ground. (2) Slide the two O-rings provided on each pin (A and B) out of their respective groove. {3) Pull out pins A and 8. Keep them clean. (4) Reverse the bucket as shown, Make sure it rests firmly on the ground, (5) Pin the arm to hole B, the link to hole A. (6) Install the pin stopper bolts and nuts to pins A and B. (7) Reinstall the 4 O-rings in their original positions. (8) Grease up pins A and B. (9) After installing the pins, be sure to check the bucket works smoothly by tuming it to its stroke-end slowly while the engine is idling, Shifting O-ring Reversing bucket, —39—Sf Basic Machine Operation FACE SHOVEL OPERATION © For face shovel operation, dig the ground using the arm cylinder in a scraping motion. © Where underground water is expected, make a slope angle of 2 to 3 degrees to drain this water as shown, A caution Take care not to hit the cab with the reversed bucket. PRECAUTIONS IN TOWING If the excavator needs to be towed, or is used to tow another vehicle, attach a tow rope as shown. ~40~TRANSPORTING A caution LOADING THE EXCAVATOR Load and unload the excavator on a level surface. Keep the trailer bed clean. Use chock blocks against truck and trailer wheels. Use a ramp or loading dock. A caution When you load or unload the excavator from the rearend long vehicle, be sure ramps are strong enough, low angle and correct height. In case frontend attachment mounted. In case without front-end attachment. A caurion (1) No levers other than propel levers should be operated at this tim When loading/unloading the machine, always turn “OFF” the auto ty. (SDX only) (2) When loading/unloading under cold weather, never fail to carry out warming-up of the ‘machine before unloading/loading operation. (See P.34) Be sure perform this warming-up for safety’s sake as well. ing switch for your safe- —a1—Transporting Center the excavator on the trailer Lower the front attachement into the carrier, and release the presure in the boom cylinder circuit. See page 74, A caution Be sure to lower the front-end attachment onto the carrier and fix with it by wire. Fasten chains to the trailer, side steps, or tie down eyes, Tighten the chains. Use blocks. —42—Transporting DIMENSIONS FOR TRANSPORTATION Unit: in mm 0 se hort 53s ei ex200 ae teas 2700 (Reacend divs) ssn 8 g “3 | wal lg 000 ® oo 4000___ | 9680 (Shore) a Gross weight: 18.5 tons exzoo.e 5 Se ans __ Ses) - 2760(Rer ena aus) | 8 ‘680 ho Gross weight: 19.0 tons NOTE The above dimensions are based on the standard EX200 and EX200LC with long arm and short arm in parentheses. As to the further dimensions on EX200/EX200LC with any other shoes, see Specification in PART II. 43TO THE MECHANIC and dealer's service personnel Read this manual carefully to learn how.to service your excavator correctly. As to more detailed information on the Isuzu Engine than that mentioned in this manual, please refer to the Isuzu Engine Instruction Book, WARRANTY The warranty on this excavator appears on your copy of the purchase order which you should have received from your dealer when making your purchase. This warranty provides you the assurance that HITACHI will back its products where defects caused by faulty work: manship appear within the warranty period. In some circumstances, HITACHI also provides field improvements, often without charge to the customer, even if the product is out of war- ranty. Warranty and field improvements are a part of HITACHI’s product support program for customers who operate and maintain their equipment as described in this manual. Should the equipment be abused, or modified to change its performance beyond the ori factory specifications, the warranty will be: come void and field improvements may be denied, Setting fuel delivery above specifi- cations or otherwise overpowering machines will result in such action. DIRECTIONS Left, right, front and rear in this manual are seen from the operator's seat facing forward, propel motors at the rear. MEASUREMENTS SI units equivalent and conventional metric system in parenthesis are used in this manual, MACHINE NUMBERS Write your machine serial number and engine serial number as well as machine model and engine type. Your dealer needs this. infor- mation when you order parts and/or when: ever you contact them. Machine model and serial number are punched on the front-end side main frame as shown. en | Engine type and serial number are stamped on the left side of the engine body, Location of engine number ‘@BDIT-500001 Engine model — Engine serial numbér —a5—Safety 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 operating practices. UNDERSTAND SIGNAL WORDS A signal word DANGER, WARNING, or CAUTION —is used with the safety-alert symbol. DANGER, identifies the most serious hazards. DANGER Safety signs with signal word DANGER or WARN- Z\WARNING ING are typically near specific hazards. General precautions are listed on CAUTION safety Z\caution signs. CAUTION also calls attention to safety mes- sages in this manual. FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your machine safety signs. Follow recom- mended precautions and safe operating practices. Keep safety signs in good condition. Replace mis- sing or damaged safety signs.Safety A caution UNDERSTAND CORRECT SERVICE Be sure you understand a service before you work on the excavator. Do not run the engine while you service the ex- cavator unless the procedure is approved. Do not start or operate the excavator unless you are in the operator's seat. Do not lubricate or work on the excavator while it is moving. Acaution BE SURE TO STOP THE ENGINE Place the machine on level ground. Lower the bucket to the ground. A caution CAUTIONS FOR INSPECTION AND MAINTENANCE Place a notice board “under inspection and mainte- nance” on the cab door or control lever. Never get under the machine while it is jacked up by the boom and arm: When inspection or servicing the machine with raised boom and arm, always use safety blocks, safety supports, etc. A caution Each part suffers high temperature just after opera- tion. If one touches parts without taking a proper step, he may burn himself. So start inspection and servicing only after temper- ature of these parts lowers down. When circumstances compel it, take full care abso- lutely to touch these parts which are exposed to high temperature. -a8—Safety A CAUTION SERVICE HYDRAULIC SYSTEM SAFETY (1) Immediately after operation, each equipment as well as hydraulic and lube oil are under high temperature and/or pressure. Start therefore the servicing only after the temperature of each part lowers down. Work under high temperature and pressure will cause burn by high temperature equipment or gushing oil or by plug/screws sprung out. Since there may remain internal pressure even in a state with lowered tempera- ture, gradually loosen the plug and/or screws avoiding facing them and then proceed to their removal only after the internal pressure dis- appears. (2) When inspecting/maintaining the hydraulic sys: tem, never fail to extract air from oil tank order to remove the internal pressure. (3) Your attention should be drawn to it that the in- ternal pressure cannot be completely removed in spite of air extraction from oil tank, at the level of cylinder circuits of boom, arm and buck- et , the pipings for swinging and those of pilot system (including accumulator). Remove residual pressure by operating several times each lever. (4)On a slope, the motor for swinging are always exposed to high pressure due to tare weight of vehicle body, and this even after extraction of air from oil tank. Never try to do inspection/servicing on a slope. (6) Pay minute attention to it that joint faces should not be damaged and that foreign matters such as dust should not enter into other hydraulic parts. A caution LOCK THE ENGINE HOOD Lock the engine hood after opening. Don't leave the hood open on slopes or in strong winds. ie 49Safety A CAUTION SUPPORT RAISED EQUIPMENT Do not work under a raised bucket. Lower the bucket to ground or onto blocks. If the bucket cannot be grounded, use the support raised equipment. A CAUTION HANDLE FUEL SAFELY Be careful when you work with any kind of flam- mable. Do not fill the fuel tank when the engine is hot or running Qt Do not smoke while you fill the fuel tank or service reo ‘the fuel system. CAUTION AVOID HIGH PRESSURE OIL Escaping oil from the hydraulic system under high pressure condition can have sufficient force to penetrate the skin, causing serious injury. Before disconnecting hydraulic lines, be sure to relieve pressure. Before applying pressure, be sure connec- tions are tight and lines, pipes and hoses are not damaged. Use a piece of cardboard or wood, to search for suspected leaks. Do not use your hand. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. A CAUTION MAKE REPAIRS SAFELY When you hit connecting pins in or out, guard your body against injury from flying pieces of metal. Wear goggles or safety glasses, safety cap, and gloves. 50.Safety A CAUTION AVOID DANGEROUS WORK Never attempt to get on or off the machine while it is operating. When getting on or off the machine, use the hand- rail and steps.COMPONENTS LOCATIONS AND CIRCUITS. GENERAL EX200,EX200LC consists of three main components as follows: Superstructure @ Cab @ Control Lever @® Engine @ Moffler ® Air Cleaner © Pumps © Batteries ® Counter Weight @ Radiator,Oil Cooler @ Fuel Tank D Reserve Tank(Cooling Water) 2 Control Valve 43 Swing Mechanism (Motor, Reduction Gears Parking Brake) @ Swing Circle 3 Center Joint (8 Tool Box @ Hydraulic Oil Tank (with a built-in full flow filter) Front-end Attachment ® Boom 9 Boom Cylinder @ Arm @) Arm Cylinder @ Bucket @ Bucket Cylinder @ Link A @ Link B @ Side Cutter @ Tooth Points @ Head Light Undercarriage @ Front Idler GD Track Springs @D Track Frame @ Track Rollers ® Carrier Rollers @ Travel Mechanism (Motor, Reduction Gears, Parking Brake) @) Shoes 36) Track Links —83—Components Locations and Grcuits HYDRAULIC SYSTEM] (sox) (1A new, patented hydraulic system is employed on the EX200, EX200LC, celled the Optimum Hydeaule System (01M) Ie features ‘Shock fre swing operation for excellent inching perlormance. Effective utilization of combined operations |2) A spare spool i provided for aditionalatachments such ata hydraulic breaker, (31 A great numberof safety valves are built inte the hydraulic circuit, These protect the circuit from damage due to excesive pressure 0° closing, (4) The propel parking brake isso structured that i is put ON and OFF automaticaly by the travel motor chive pressure, Its released by operating the Wavel(oropal) lever, and He ‘ppled by taking aff your hand (6) The swing parking brake is interlocked with the sting, boom, arm and bucket levers, and ‘is put ON and OFF automaticaly. Iie released by operating the swing, boom arm oF bucket Iver, and is applied automaticaly after putting back the lever. (6) This machine 4 equipped with an accumulator, which allows to move the frontend tachment for some time alter the engine has stopped. Az contain high pressure gos ever detach it rom the machine body, dsmentie tor trow int mes, (7) The all nysraule components, inelucing the hydraulic pump, conte valve and switch valve, have Bsn acjustad athe time olfactory delivery (Do not dismantie these components nor touch the adjustment screws: once demounted, they are no longer readjustable. In case of any abnormality, slays inform the nearest @ Bucket evinder 68 Ful tow titer 23 Control vaive @ Arm evlinder 1 Center joint 2% Front pump @ Boom eylinder 48 Swing motor 2 Rear sume © Travel plot vabe 4B Parking brake selection vale 38 Engine ) Let pilot valve GP Bypass check valve 28 Radiator © Right pilot vaive 4 Trove! (ett) {Oi cooler P Control nevtsizer valve AD Travel (right 0 Accumulator @ Shockless vabe 2 Spare 2 Pilot eum Restrition vale Bucket AaB Mode selection cylinder 9 Check valve @ Boom BW Solenoid valve {1p Oi tank a Arm 38 Pilot fer {Suction sesiner 26 Swing 8 Propel motor _Sunpiy Hine fom pues Suction ie — Aetuntor ine <=== Drain and pitt line[Components Locations and Circuits HYDRAULIC SYSTEM] (0x) (1A new, patented hydraulic system is employed on the EX200, EX2001C, called the Optimum Hydraulic System (0.4). Ie festures ‘Shock fre swing operstion for excllent inching performance. Effective utilization of combined operations. (2) A spare spools provded fr addtional attachments such a a hydraulic breaker (3) A greet numberof safety valves ae built inte the hydraulic cteuit. These protect the circuit from damage due to excesive pressure or clogging (4) The prope! parking brake is so structure that travel motor drive pressure. is relessed by operating the travel (propel lover. and is applied by taking of your hand (8) The swing parking brake i interlocked with the swing, boom, am and bucket levers, and is put ON and OFF automatically. fis released by operating the swing, boom arm or bucket lever, and is applied automatically afte puting back the lever (6) The all hydraulic components, including the hydraulic pump, contol valve and switch ‘valve, have been adjusted at the timo of factory delivery De not dismantle these components nor touch the adjustment screws; once demounted, they are no longer reagjustable. In case of any abnormality, always inform the nearest service shop, Bucket cylinder 1B Full flow titer @ Control valve @ Aum eylinder Center joint 3 Front pump ® Boom eylinder {5 Swing motor 2 Rese sump @ Travel plot vale A Parking brake selection valve Engine Lett pilot vale Bypass chec vale 2% Radiator © Right pilot valve { Teavl (ot) 0 Oil cooler Control neuratizervaive 19 Travel (ght 4) Pilot ump @ Shocks vabe 2 Spare Pilot raliet valve @ Retrietion valve 2) Bucket 88 Pict fer 19 Check valve Boom 8 Propel motor 1) Olt wnk a Am {8 Suction strainer ® Swing supp ine fom pumps Suction tne Em Rete ine Drain and pilot tne1 the fearh type system. For additional details, eterMAINTENANCE CORRECT MAINTENANCE AND CHECKING PROCEDURES Should be followed to keep the machine in the best condition. It is important for you to bear the following items in mind. © Controls and instruments — normal function and safe operation © Water, Fuel and Oil — leak, level and sediment build up. © External appearance, noise, heat, etc. . Nuts and bolts — looseness Damaged, worn, or missing parts. | Le rmissnopats In case that any abnormality is found by checking or during operation, repair immediately. If you have any questions about the problems, contact your HITACHI dealer. IMPORTANT © Use recommended fuel and lubricants. © Use recommended genuine HITACHI parts. © Never adjust the engine governor, or main relief valve. NOTE The warranty will be void if fuel or lubricants other than those recommended are used SERVICE YOUR EXCAVATOR AT SPECIFIED INTERVALS Lubricate, make service checks and adjustments at intervals shown on the periodic service chart on pages 64, 65. Intervals on this chart are for operation under normal conditions. If you operate the excavator under hard conditions, then you should service it at SHORTER INTERVALS. Use the servicemeter reading to determine when your excavator needs periodic service.MAINTENANCE GUIDE A. Greasing (See p. 66) sn oer ae or 1. Front joint pine Bucket a ters a 2. Swing bering 3 Swing ger a Engine oil (See p. 69) Oi evel check e 1 eine oi pn EES a 7 Engine ol Fiker | peniacoment repiecement Feptcaren 70 5 fterretairenr _ | Renacement n ©. Gear oil (See p. 72) Pans Poon Oi vet check 78 Feplacement 2. Swing reduction (it evel check oevieo Replacement 3. Propel reduction (il evel check sevee Replacement D. Hydraulic system (See p. 76) Poe 1 Hyeraulie ot evel check 2. Hydraulic oi tonk draining Hydraulic ol epi 6. Pilot hte element replacementMaintenance E. Fuel system (See p. 85) Tank capacity: 310 tt Interval ‘Hours Pons Quantity re Page 2 [| 50 | 100 | 250 | soo | 1000 | 2000 1. Fuel tank water draining 7 te 2,_Watersadimenter checking 7 3. Fuel filter element replacement 1 = 6 4. Feed pump strainer cleaning 1 5 @ Tatenal (ours) Parts Quentiey Page [2 Tse | 100 | 260 | s00 [1000 | 2000 Tawaaaeng Gearing 7 JOrwhen warning mp it 8B fement Replacement 1 ‘After cleaning 6 times or 1 year | 88 2 Awaworerian Replacement 1 [At time of outer element a G. Cooling system (See p. 89) Tava hana cuey - eae 20 | sm [om | wom Trae rt tng 7 0 7 Goolng weer lear 7 my a 4 Radiator core Outer core 1 | | ey ears 1 Z ny 5. Oil cooler front net cleaning I a 92 H. Electrical system (See p. 93) 1. Others (See p. 95) Treat Faw) pana cuney rooe 7 [= | | a | mo [om [oe “Tin iooh noonlighe Being we 2: Trek ender eeckng 7 7 SES Rhian cen : Tana he 7 bow count eaing ] Cote NOTE ["%_] Grease every 8 hours till initial 100 hours. [3642] Items to be done during under-water operation. Items to be done only first time check. NOTICE An lubricant name plate is affixed on the inside of the tool box cover. —65~Maintenance r A. GREASING ats vanity ioe tow Page [= | wo | 20 | sw | soo | 2000 Ewan) a 1. Front jot pins [ucket 8 67 thers 7 o 2 Swing bearing [2 @ 3 Swing ae 7 @ The brand names of recommended Grease = OH Were to be “Steves Manufacturer ‘British petroleum Caltex of Exo standard oi emia Kosan Mobil ot Remarks 2040" 8? Energrene user? Manion EQ Coe 2 Front joint pins ‘Swing gear, swing bearing te Daphne Coronex Gresie €P2 Mobiiux ere ‘Shell Alvania EP Gree Lithium soap grease with ‘extremely high loadearying ailty NOTE The machine shipped from the factory is filled with lubricants marked with *. —66—Maintenance 7 | Front joint Pins Boom foot, Boom cylinder bottom and bucket (1) every 50 hrs. (every 8 hrs ti 100 hrs) Grease all the grease fittings as shown. A centralized greasing system is provided for quick and safe lubrication of the higher greasing parts. Boom cylinder bottom, (2) Bucket and Link pins—every 50 hrs. (3) Ohter Pins—every 100 hrs. ‘Arm cyl. rod pin and Backet_ Boom and arm joint pin cyl. bottom pin NOTE By keeping the front attachment in the trans. port posture (the boom lowered and the bucked landed, with both the arm cyliner and the bucket cylinder extended at maximum), all necessary parts can be lubricated in this one posture. Zz s 4 Boom cylinder rod pins and arm cylinder bottom pin (A centralized greasing) 67Maintenance Swing Bearing — every 500 hrs. There are two grease fittings. (1) Lubricate the bearing through the grease filting while the swing body is kept stationary (2)Stop greasing and rotate the swing body by slightly turn Repeat the said procedures (1) and (2) two times. 3] Swing Internal Gear = every 500 hrs. (1) Removing Grease Remove the cover at the bottom of the swing internal gear housing. Scrape all the old grease out from around the internal gear. (2)Replacing Remove the cover on the frame as shown. Then put in new grease. making sure it gets to all the internal gear teeth, while repeat swing and stop motion.Maintenance B. ENGINE OIL Tnterval our Parts Quantity — age 8 50 100 | 250 | 500 | 1000 | 2000 i er = ‘aing @il pan Replacement | 26.5 ti [ 70 % Engine on ter | Repiacement | 4 70 zt = 2 Erased | Reviscemene [Ot [ n Recommended lubricants Use engine oil properly comforming to the atmospheric temperature. API. CD Class Normally, equivalent to SAE 30 (both summer and winter) In hot areas, equivalent to SAE 40. In cold areas, equivalent to SAE 10W. The brand name of lubricating oil _ _ _ recommended montana | 2°06 [| soe | asnwre sao] so" vee ‘00 ‘#The machine shipped from the factory is pan oi Feo, Mists 1a filled with lubricants marked with" ee) Engine oil pan — level check daily Check the oil level before starting the engine. The oil level should be between the circle marks on the oil level gauge, When the oil level is insufficient, refill with recommended oil through the oil filler. Then recheck the oil levelMaintenance Engine Oil Pan ~ replacement every 500 hrs. Acauron ovine Since each part of engine undergoes high tempera- ture just after operation, start work only after the temperature lowers down. Container Clean cloth (1) Draining oi! Remove the drain plug from the engine oil pan. NOTE: Make sure you have a container capable of holding 50 liters and a clean cloth. Drain the oil through the clean cloth into this container. Chech if there is any foreign matter in the cloth such as small pieces of metal (2) Filling Make sure the drain plug is in and done up tightly. Then remove the oil filler cap and fill 26.5 liters of engine oil (3) Oil Level Check The oil level should be between the "H” and marks on the dip-stick Run the engine for a few minutes at idling speed then recheck the level after stopping the engine. Engine Oil Filter Element ~ replacement every 500 hrs. A caution Since each part of engine undergoes high tempera- ture just after operation, start work only after the temperature lowers down. (1) Loosen the drain plug at the bottom of the cart ridge filter, and drain the oil in the filter (2) Remove the cartridge filter by turning it counter- clockwise with a tool (3) Apply engine oil lightly on the gasket surface of a new cartridge element, and turn it clockwise slowly by hand until it touches the seal surface. (4) In this condition, fasten it further 3/4 ~ 1 turn by using a filter wrench, Do not fasten it too strongly, as it may crush the filter —70~Maintenance (5) When the oil filter warning lamp lit on the monitor in operation, the filter element is clogged. In this case, replace the element regardless of the replace: ment interval TE (1) Do not use cartridge element repeatedly. (2) Be sure to replacement the gasket with a new one contained in the element kit (3) For installation, be careful not to twist and damage the gasket (4) Bun the engine, and confirm no oil leak Engin Oil bypass Filter Element —replacement every 500 hrs. rn CAUTION Since each part of engine undergoes high tempera- ture just after operation, start work only after the temperature lowers down. {1} Remove the upper and lower plugs of the bypass oil filter, and drain the oil (approx. 3 lit) (2) Detach the clamp by loosening the fixing bolt, and remove the cover and gasket (3) Remove the element by holding its handle. (4) Clean the inside of the body and the cover. (5) Secure a new element with a specified torque (9.8 ~ 11.8N-m or 1.0 ~ 1.2 kgfm) and replace the packing (6) Set the cover, attach the clamp and fasten it by Using a spring washer and a bolt with a specified torque(13.7 ~ 17.6 N-m or 1.4 ~ 1.8 kgf-m). (7) Fasten the upper and the lower plugs with a speci- fied torque (14.7 ~ 19.6 N-m or 1.5 ~ 2 kgf-m) after inserting packings. A caution (1) Never replace the oil filter while the engine is operating. (2) After the engine has stopped, wait until the body cools down for replacement. NOTE (1) After replacing the element, start the engine and check any leakage. (2) When replacing the element, use a special care so as not to damage the surface of the filter. (3) Any damaged packing, incomplete seal, and plug/ bolt with a damaged screw part must be im- mediately replaced with a new one. (4) When only the filter has been replaced, check the oil level in the oil pan after operating the engine for a few minutes, and supply engine oil if neces- sary. neMaintenance Cc. GEAR OIL Interval (Hours) Pars Ouantity Poe a_|_s0 | 100 | 250 | s00 | 1000 | 2000 Oittewei check | _— 73 1. Pump tensmission -— = 4 te ~ Replacement | 1.3.8 | 3 2 Swing reduction | Ollevel heck | = }+——4. zs ever Repiocement | 751 74 3. Propet reduction | Oitlevetcheck | __[ 78 The brand names of Gear oil recommended Kinds of ubrcans| (Gea it nee tobe | Swing, propel reduction devies “Sotied_ | Sha pump transmission Manutacture 70 Britin pevoiaum [BP GeurOi SAE 9DEP Caltex oi ‘Universal Thuban SAE 90 Exo nanderd ot [Eno GearOl G90 Naor P00" Nippon of cor Lube poh OO Shel oi [She Spire EPO Remarks | API GL4 Class ‘The pear oll marked * or ** is applied to anew mechine, ** Pump transmission only * Swing and prope! reduction devieos —n-Maintenance | Pump Transmission — every 1000 hrs. A caution Since each part of engine undergoes high temper: ture just after operation, start work only after the temperature lowers down. Checking oil level — every 250 hrs. (1) Keep the machine body horizontal, (2) The oil level should be between the scales of the oil level gauge. Gear oil replacement — evey 1000 brs. (1) Draining Firstly, remove the plug at the top of the transmission case. Then remove the drain plug at the bottom as shown, NOTE Make sure you have @ container capable of holding 2 liters and a clean colth. Drain the oil through the cloth into this container. Check the cloth carefully for foreign matter such as small pieces of metal. Oi pan Ciean cloth Container (2) Supplying gear oit 1. Keep the machine body horizontal. 2. Remove the plug from the oil inlet, and supply gear oil sbout 1 lit. Use Nisseki SPB0W-90 or equivalent. 3. Remove level gauge and check that oil is at the H in the level gauge. 4. Reset the level gauge and the plug, Level gauge —n—Maintenance D| Swing Reduction Unit every 1000 hrs. Since each part of engine undergoes high tem- perature just after operation, start work only after the temperature lowers down. Oil level Check — every 250 hrs. Park the machine on level ground, The oil level should be between the scales of the oil level gauge, if the oil level is insufficient, refill oil. Gear oil replacement — every 1000 hrs. (1) Draining Take off the top plug (P) of the drain cock (6) , and ‘open the cock to drain the oil (2) Filling Make sure the drain plug is in and done up tightly. Then fill the gear oil mmMaintenance Propel Reduction Device Oil — every 2000 hrs. A caurion (1) Each part of travel device suffers high temperature after operation. Start therefore your work only when the temperature comes down. (2)In some cases, there remains an internal pressure in travel device. Loosen gradually the plug by 2 to 3 threads, extract completely internal air or oil and then detach the plug. Loosening the piug at a breath will sometimes cause plug or gear oil to pop out or gush, therby injuring the worker. Oil level check — every 250 hrs. Place the machine as horizontally as possible. Loosen the air drain plug in the position indicated in the right figure, and slowly drain air. Then, remove the oil level check plug, and supply oil until it flow from the thread part of the plug. Air drain plug (Oit supply plug) Oil level check plug Horizontal ail leve Gear oil replacement — every 2000 hrs. Drain plug (1) Draining oil Release the air drain plug in the position indicated above figure above the horizontal level drain the air. Then, remove the drain plug and the air drain plug, and the gear oil is drained. Tighten completely the drain plug. Then move the oil level check plug, Supply oit from oil filler port up until the oil streams out of this port. When oil comes out, the librication is over. Retighten the lubrication plug, IMPORTANT Tighten the plug with 5 kgf-m (49 N-m) of tighten, ing torque wrapping it with a seal tape. (2) 78:Maintenance L r D. HYDRAULIC SYSTEM | 50 | 100 | 250 | s00 | 1000 | 2000 _2. Hydraulic oi tank a 7 1 % 3. Hydraulic oi! replacement —_ | 2201 | | 78 5. Fulkflow filter element replacement 1 T a 6 Pilot filter element placement 7 EE 2 The brand names of recommended hydraulic oil Kinds of latricans Neus Manutocture SButish petroleum Caltex i Rena oi HO32 Esso standard ol NuTO 492 Daphne Super Idemitsu Koran Hydraulic Flug LAS Mobil Nippon oi Hyland wide 32 - © Use hydraulic oil properly in accordance with the hat oi Shell Tellus oil K32 atmospheric temperature. Remarks Antinear tye hydraulic oi © The machine shipped from the factory is filled * th lubricants marked with * —16~Maintenance B caution When servicing a hydraulic equipment, draw your due attention especially to the followings: (1) The work should be done on a flat place. (2) Ground the bucket and stop the engine. (3) Hydraulic oil and lubrication oil undergo high temperature and pressure just after operation. Start therefore your servicing work only when the temperature goes down at each part. In the event that one works under high temperature/pressure, he may burn himself by equipment under high temperature/gushing oil or hurt himself by popped out plug or screw. Since there may remain some internal pressure even if the temperature lowers down, loosen, if required, the plug or screw gradually after the internal pressure disappears and in avoiding to face them. (4) When proceeding to inspection/servicing of the hydraulic system, never fail to extract air of oil tank in order to remove the internal pressure. (5) At the level of cylinder circuits of boom, arm and bucket as well as at the level of pipings for swinging and those of pilot system, the internal remaining pressure cannot be completely removed even if air is extracted from the oil tank. (6) On a slope the circuits of running and swinging motors are always exposed to high pressure due to the tare weight of vehicle body even after air is extracted from oil tank, IMPOTANT (1) Pay your minute attention to it that joints should not be damaged and that foreign matters such ‘as dust must not enter into other hydraulic parts. (2) Replenish, as occasion arises, the hydraulic oil of same brand without fail. Never try to mingle with that of different brand name. Since "DAPHNE SUPER HYDRAULIC FLUID LW46” oil is applied before ex-work, never fail to replace this oil by another in all quantity in any case. (3) Never try to use a hydraulic oil other than those specified in the Table of Recommended Lubri cating Oils. (4) Never try to start engine with hydraulic oil extracted, ] Oil level check — every 50 hrs. (1) Place the machine on firm and level ground, lower the bucket to the ground, with the bucket cylinder extended fully and the arm cylinder retracted fully. (2) Check the oil level in the oil level gauge on the side of the oil tank The oil level should be between the max. and min marks of the oil level gauge. -7-Maintenance 2 | Hydraulic Oi! Tank Draining every 250 hrs. After leaving the body in static state for a long time, extract air from tank and then loosen slowly the drain plug D on the bottom of tank to discharge remaining water and deposit. A caution Should this work is done just after operation, high temperature hydraulic oil may gush to cause burn. 3] Revlacing hydraulic oi — every 2,000 hours CAUTION After leaving the body in static state for a long time, exhaust the oil. Should this work is done immediately after operation, high temperature hydraulic oil may gush out to cause burn. (1) Keep the frontend attachment in the posture indi cated in the figure, (2) Remove the air breather cap, and drain the air in the tank. How to remove air breather cap. 1. Insert a hexagonal wrench (4mm) through the hole provided on the lateral side of the side block 2. Turn the wrench clockwise, and turn the cap counter-clockwise about 30°, at which point stop the cap for a second to release the air Turn the cap further until it stops, and take it off A caurion ‘Quick turning of cap is dangerous because it may pop out by internal pressure. Turn this slowly and detach it only after the internal pressure escapes completely. 3. To reset the cap, align the projected part of the cap with that of the case, insert the cap, and turn it clockwise until it locks. NOTICE For removing the cap, be sure to use @ hexa gonal wrench to release the lock Filter cate cover a Sa —78—Maintenance (3) Drain oil 1, Prepare a container with a 200 lit. capacity. Remove the oil inlet cover, and drain the hy- draulic oil into the container -by using an oil pump. 2. Loosen slowly the drain plug on the bottom of the oil tank, and drain the oil completely. (4) Supply oil 1. Take off the top cover of the hydraulic tank, and supply oil 2. Release the air drain plugs on the top of the right and left pumps to drain internal air, and supply hydraulic oil in the pumps. 3. When the pumps are filled with hydraulic oil, ‘temporarily fasten the plugs, start the engine, and keep it idling Loosen the air drain plugs a little, and drain internal air until the hydraulic oil leaks out from a gaps. WI After draining air, fasten the plugs completely. ct IMPORTANT y we Be sure to supply hydraulic oil in the pumps, as ON empty pumps will be broken bystartingtheengine. * ‘ (5) Drain air in hydraulic circuit After refilling oil, drain the air in the hydraulic circuit by running the cylinders and the swing motor uniformly for 10 ~ 15 minutes. The pilot circuit is equipped with an air drainer, and 0 the air can be drained in 5 minutes by the above operation. (6) Check oil level 1. Put back the front attachment to the posture for checking 2. Check the oil level. if it has lowered, refill —79-Maintenance | Cleaning suction filter — When replacing hydraulic oil A suction filter is provided at the bottom of the tank. It should be cleaned each time the hydraulic oil is replaced. After draining the hydraulic oil, remove the cover attached to the air breather, pull up the rod and take out the filter. Clean the inside of the tank and the suction filter. For resetting, make sure that it is in- serted firmly into the pipe. Before attaching the cover, be sure to insert the top edge of the rod through the hole of the cover support. After confirmation, fix the cover with bolts. Tightening torque for the retightening or additional tightening of suction filter lock nut is in the range of 14.7 ~ 19.6 Nem (1.5 ~ 2.0 kgf+m). IMPORTANT Filter Inspection When you change filter elements, inspect the old element for foreign matters such as debris of copper alloy, aluminum alloy, or others. In this way, you can monitor waste content and locate any malfunctions.Maintenance Replacing full flow filter element — every 500 hours (1) Remove the air breather cap of the hydraulic oil tank, and drain the air. For detaching/attaching the cap, refer to the sec- tion of hydraulic oil replacement A caution Quick turning of cap is dangerous because it may pop ‘out by internal pressure. Turn therefore this slowly and remove it only when the internal pressure re- leases thoroughly. (2) Loosen the 6 bolts (1), and take off the cover (2) and the O-ring @) A caution Never reverse these procedures, as it may cause the oil to pour out. A caution ‘The cover (2) should be removed carefully so as not to cause the spring @ to jump out. (3) Take out the spring @), valve ©, and element @ (4) Replace the element with a new one, together with the O-ring @) (5) Fasten the bolt (1) completely (fastening torque 49 N-m or 5 kgf-m) IMPORTANT are empty, the pumps will be damaged. @oxing @eover F geo Element NEVER start the engine before filling up both pumps with hydraulic oil. If the pump housings 81Maintenance Replacing pilot filter element — every 1,000 hours (1) For replacement, disassemble the element in the following procedures: (2) To detach the filter, loosen the case (6) and take it out by pulling it downward. Detach the element @ by unscrewing it downward, (3) Before reassembly, replace the O-ring @) with a new one, Reassembly procedures (1) Insert a new O-ring @) into the O-ring groove on the head cover () (2) Assemble the element @) firmly with the head cover (B) by screwing it upward (3) Attach the case @), and tighten the element completely. (Tightening torque: 19.6 ~ 29.4 N-m or 2~ 3 kgf-m) A caution Before replacing the element, never fail to push the air breather valve of hydraulic oll tank to purge the air from tank. k turning of cap is dangerous because it may pop out by internal pressure. Turn therefore this slowly ‘and remove it only when the internal pressure re- leases thoroughly. NOTICE (1) Take full care never to allow any water nor dirt into the filter case. (2) Pay your due attention to it that the elements and O-rings should not be damaged. An elements, once broken, cannot be used again any more. 3) After replacement, proceed to oil level check and air purge. Air penetrating into the circuit may pos- sibly cause the pump to be deteriorated. (4) Elements should be replaced or cleaned periodical- ly to keep the hydraulic oil clean and to prolong the service life of the hydraulic equipment. —82—Maintenance FOLLOW THE CORRECT PROCEDURE FOR HYDRAULICS Pay attention not to damage the jointing surfaces of hydraulic components, (a) Thoroughly wash and clean pipes, hoses oil tank, etc. before assembly (b) Use undamaged O-rings, and take care not to dam: age them during assembly. (c) When connecting high pressure hoses, do not twist the hoses, or their service life will be shortened. {d) Tighten the low pressure hoses clamp to a torque 0f 5.9 ~ 6.9 Nm (0.6 ~ 0.7 kgf-m) (e) The following 2 types of joints are used for the hoses and pipings: (1) O-ring seal joint ‘An O-ring is attached on the end surface of the adaptor to prevent oil leaks at joints. Construction O-ring groove Seal surface J, PIs. Adaptor owing Union Hose or pipe NOTE (i) For reassembly, always replace the O-ring with anew one. (ii) Before fastening the union, always confirm the O-ring is properly set in the O-ring groove. If the O-ring is off the groove, fastening the union will damage the O-ring and cause an oil leak. (iii) Reassemble the joint so as not to scratch or damage the surface of the O-ring groove on the adaptor and the seal surface of the hose ‘A scratch on these surfaces may damage the O-ring and cause an oil leak. 83iv) If oil is leaking from a loose union, first con- firm if the O-ring is set correctly in the groove before tightening the union. Here again, be sure to replace the O-ring with a new one. (v) Fastening torque Use the following torques for fastening the unions: 10% Wiath across tate | on 2 | 2 | a [eras . 9a | 1372 | 1764 | 2058 [iotm [os [a [ve [2s (2) Metat seal joint (Union nut; width across flats: 19, 22) It seals the pressure oil by the adaptor and the metal part of the hose. It is used at joints with a relatively small diameter. For disassembly and reassembly, be careful not to damage the seal surface. With acre fats (om) 19 2 wm 204 392 Festening torque ligt) 3 aMaintenance —, FUEL SYSTEM Tank capacity: 210 tt Interval (Hours) Parts Quontty 100 | 250 500_| 1000 | 2000 1 Fuel tank water daining 2. Water edimenter checking 3. Fuel filter element replacement 44 Feed pump strainer cleaning 7 RECOMMENDED FUEL Use high quality diesel fuel only (JIS K-2204) (ASTM2. D) Kerosene must not be used REFILLING Fill the fuel tank at the end of each day’s operation, Fuel tank capacity: 3108 IMPORTANT Keep all dirt, water or other foreign materials out of fuel ~85—Maintenance 7 | Feel Tank Draining every 8 hrs. After leaving the body in static state for a long time, remove the top plug of the drain valve located at the bottom of the fuel tank, and open the drain valve to drain water and deposits The plug is attached to prevent vandalism. D| Water sodimenter checking — every 60hrs ‘A water sedimenter separates the water mixed in fuel It is a case containing a float, which comes up when water is accumulated. When the float has reached the "Water-drain level” indicated on the outside of the case, drain the water. How to drain water Loosen the plug on the upper side of the water sedimenter. Then, loosen the lower drain plug to dis- charge the water accumulated inside After the drainage, be sure to fasten the both plugs, NOTICE After draining water from the fuel, also drain the air mixed in the fuel. (See “Air Bleeding” in the section of FUEL SYSTEM) Drain the water earlier if its content is large in the fuel Replacing fuel cartridge filter wvery 500 hours (1) Detach the cartridge filter by using a tool For safety and so as not to soil the ground, make sure that the fuel is collected in a container. (2) Apply fuel lightly on the gasket surface of a new cartridge filter. (3) To reassemble the cartridge fitter, turn it slowly by hand until the gasket touches the seal surface, (4) In this condition, tighten the filter by another 1/2 ~ 3/4 turn by using a filter wrench. Here, use a proper wrench and be careful not to tighten too strongly, as it may crush the filter. (5) Draining air from fuel After replacing the fuel filter element, drain air contained in the fuel system (See “Bleeding Air” in the section of FUEL SYSTEM)Maintenance ae ir bleeding Feed Pump strainer — every 1,000 hrs, Loosen the joint bolt of the connecting inlet hose of the feed pump, Remove the joint bolt and loosen the strainer from the inside of the joint bolt with a screw driver. Clean the inlet filter with diesel fuel Point to Note © Air Bleeding When the fuel filter, water sedimenter or feed pump. strainer inlet filter is serviced, air can enter the fuel lines. To remove this air, loosen the air bleed screw of injec: tion pump using a driver and a spanner. Turn the handle of fuel priming pump to slacken it, move the to handle up/down manually and feed in the fuel until foams disappear from the air bleed screw. When the Strainer foams have disappeared, tighten up the air bleed screw first, and then restore the handle of priming pump to its original position —87—Maintenance F. AIR INTAKE aa] Air Cleaner Element cleaning every 250 hrs. ‘or when warning lamp lit Replacement: After cleaning 6 times or 1 year [Cleaning or replacing outer element] (1) Loosen wing nut and the outer element. (2) Clean the air cleaner body interior (3) Clean the outer element by blowing compressed air through it from the inside © Replace the outer element which has been cleaned 6 times repeatedly or used through out a year. Replace the inner element at the same time © Check inner element mounting nut for loose- ness and, if necessary, retighten. {Replacing inner element) (1) First remove the outer element, and then remove the inner element. (2) Clean the air cleaner body interior. Then fit a new inner element and tighten it with nut B caution Put on your goggles when compressed a is used. — NOTE — This machine is provided with an air cleaner clog warning lamp which lights up in the monitor panel when the air cleaner’s filter element becomes clogged. When the lamp is lit, clean or re place the filter element as soon as possible, The element can be easily removed from the cover side Filter element Body f Re Air intake pipe Safety fur Dust element Air cleaner clog warning switch Valve A caution (@) Be sure to stop the engine when servicing the filter. (b) Check all hoses and pipes for loose joints or connections, every 250 hrs. 28Maintenance G. COOLING SYSTEM rw Gentiy 160_[ 250 | 00 [1000 [2000 |" 1 Water vel checking 1 90) 2. Fan bet tension check 1 | fae 20 3. Cooling water replacement 2a a 4. Radiator core Outer core ‘ st lenin Inner cove 7 TI a 5. Oi cooler front net cleaning 4 2 L i Only fst tie check (1) Cooling water Use soft or city water, as free as possible from scale forming minerals, Use anti-rust agent in the radiator, at all times, (Amount of antirust mixed: 460 cc) (2) Antifreeze When the outside temperature is anticipated to fall below freezing temperature, anti-freeze should be used in the cooling system. Normally the density of antifreeze should be 30% to 60%. At a density below 30%, rust may occur, while over 60%, the system may overheat. Anti-freeze Mixing Ratio Anti freeze Outside temperature cethvenaveon Soft water 1 69 16.1 “4 69 16.1 “7 69 16.1 " 69 16.1 -15 83 147 -20 92 ] 13.8 25 | 10.1 | 129 -33 15 | 15 -50 13.8 | 92 =Maintenance i] Coolant level check — every day Check the coolant level when the engine iscold. Coolant should be at the level between Full and Low of the reserve tank, When the coolant level is under the Low level, refill coolant into the reserve tank. However when the reserve Tank is empty, refill coolant through the radiator cap. Acaunon Do not remove the cap of radiator if the temperatore of radiator water is high. Otherwise, high temper: ture steam may blow out abruptly causing burn, After the temperature of water goes down, loosen gradual- ly the cap to reduce the pressure and then remove it. In the event that it is impossible to wait up until the water temperature lowers down, draw on your gloves, apply cloth to the cap and loosen it slowly to release the pressure. Pay your minute attention to it that you do not touch hot water. Fan belt tension — check every 100 hrs. (initially 50 hrs.) Check the belt's tension so that the fan belt can be depressed about 10 mm with the thumb (with a force of 98N (10 kgf}) midway between the fan pulley and alternator pulley. Adjustment of the belts tension can be done by pivoting the alternator pulley after the fixing bolt for alternator pulley adjusting plate and alternator pulley bracket have been loosed. Check also the fan belt for any defect. If any defect is detected, replace it. Fan pulley Push t (98n) 10 mm (10 kat) t 7 ‘Alternator pulley Crank pulleyMaintenance 3] Coolant Replacement — every 500 hrs (1) Draining Drain the coolant by opening the drain cock at the bottom of the radiator and at the water jacket (2) Filling Coolant and Level Check Refill the radiator with soft water Run the engine for a few minutes, then check the coolant level Radiator Core Cleaning (1) Outside — every 500 hrs. Clean the radiator core by water or steam. The radiator fin may be damaged if the delivery pressure of cleaning steam or water is too high. When the delivery pressure is higher than 6Okg/cm?, keep the nozzle more than 500mm away from the core surface. A CAUTION Put on your goggles when compressed 2) Inside (flushing) — 1,000 hrs. Flush the cooling system every 1,000 hrs using neutralized radiator cleanser to remove rust, scales and other deposits. After flushing, wash the entire cooling system using generous amounts of water. It is not recommendable to use alkaline base cleanser for flushing since they are corrosive to the parts of the cooling system. aMaintenance 5 | Cleaning front net of oil cooler — every 500 hours When the machine is used in a dusty environ. ‘ment, check the net every day for dirt and clog. ging. If clogged, remove the net and clean it. —92—Maintenance H, ELECTRICAL SYSTEM For the detailed information of the electric system, refer to “Operation manual for Isuzu 6BD1-T Diesel Engine”. A CAUTION Battery A battery produced inflammable hydrogen gas liable to cause ignition and explosion. Further, the battery is filled with sulfuric acid, which can eat through clothing and burn flesh, even metals. So, it must be handled with the greatest possible care, @® Never smoke or cause a spark near the battery. @® If the battery acid gets on your skin or clothing, flush with cold water and then soap earefully. If the battery acid gets into your eyes, flush with fresh water immediately for about 15 minutes and then, get medical attention. ® Don't finger the battery terminals immediately after the operation is finished. It is dangerous. Wait the battery for cooling moderately. Prior to servicing and checking the battery turn off the load (engine key switch) to stop the engine and detach the vent plug. © When removing the battery terminals, be sure to do it from the earth side one terminal). When attaching the other way, do the earth-side terminal later. If a tool ‘comes in touch with ( wire of earth-side terminal is left connected, a spark occur, which is dangerous. © Clamp the terminals securely. if they are loose, a spark may occur. ® When charging the battery, inflammable hydrogen gas is produced. So, charge the battery taking it off the machine and detach the vent plug. Maintenance of MF (maintenance-free) battery Since the battery performance has serious effect on the starting performance of the engine, correct maintenance is required for the battery. In MF battery, the reduction in battery fluid during use and self-discharge are little compared with general batteries. Perform the maintenance of the battery following the procedures below Since the specific gravity of the battery fluid differs depending on the fluid tempera- ture, the specific gravity should be kept within the range shown in table below. | 20°C. t Working range r s Fluid temp, - __t T2122 123 128 1.26 126 1.27 128 1.29 130 1391 132 ———_> Specitic gravity of battery fluid —93—Maintenance A caution Measure the specific gravity of battery fluid when the fluid temperature has nearly become the atmospheric temperature, but not immediately after the operation. operation. @® _ Check the terminals for looseness and rust. Corrosion can be prevented by applying grease or petroleum jelly to the terminals, @® Always keep the battery surface (terminals and vent plugs) clean. It can preferably prevent the battery from getting exhausted up. @ When replacing the battery because it has become old, replace 2 batteries as a set. It is because that when new and old batteries are used together, the life of new battery will reduce. ® Avoid using a general battery and MF battery together. It results in the advantage of MF battery being offset. Cigarettes, flames or sparks could cause battery to explode. Always st (3), Start-up by booster cable When using a booster cable for a dead battery, observe the follwoing instructions: ® _ Stop the engine of the machine. ® Connect one end of the booster cable {red to the @ plus terminal of the battery on the machine having trouble, and the other end to the same of the other ma chine, @® _ Then, connect one end of the other booster calbe (black) to the ©) minus termin- al of the battery on the other machine, after that, the other end to the superstruc- ture of the machine having trouble. At that time, connect it to the point apart from the battery as far as possible, be- cause a spark is unavoidable when the cable is connected at last. @® After connecting them securely, start the engine on the machine having trouble. ® After starting the engine, remove the booster cable in reverse order. A CAUTION EXPLOSIVE GASES Id eyes and face from battery. Do not charge or use booster cables or adjust post connections without Proper instruction and tra ing. Keep vent caps tight and level.Maintenance 1. OTHERS Interval (Hours Parts Quantity T Pooe 2 | 0 | 100 | 260 | soo | 1000 | 2000 1. Bucket teeth loosening/wear enecking D8 2 Track tension checking 2 L 97 3. Bucker-fning pn clearance aud : 2 ssiustment ‘ 98 Bort loosening checking ERE RHA] ony tire time check —95—Maintenance T] Bucket Teeth Check the bucket teeth for wear and looseness: (1) If the wear is excessive, replace them with new ones, Service Standards Standard Recommended Dimensions A. Service limit Service limit 200 mm 115mm 95 mm (2) Push the rubber pin lock into the nose hole. (3) Put the point over the nose. (4) Drive the locking pin into the hole fully. —96-Maintenance 2D] Trask Tension Check — every 50 hrs. The track link tension can be adjusted hydraulically by charging grease into the adjust cylinder through the grease fitting or bleeding it from the valve. Jack up the machine as shown, Check the track link slack by measuring the height from the upper side of the shoe to the side frame bottom, as shown. For normal ground conditions, set the slack to 310 to 330mm, for sandy soil to 370mm and for muddy ground to 330 to 370 mm. In case of loosening track link Put socket (tool; long socket 24) on the hexagonal part of the body of valve @ and loosen the valve as a whole little by little for discharging grease. Do not loosen the valve more than 1.5 turns (loosening 1 to 1.5 turns is enough), If grease is not discharged well, jack up the track of the loosening side and turn the track link slightly. Af- ter completion, retighten the valve (1) as before. Tight- ening torque: 15 kgf.m. A caution It is dangerous to loosen the valve (1) too much or loosen abruptly as highly pressurized grease in the ing Valve Grease discharge hole adjusting cylinder is spouted out. Loosen the valve ®@ Fitting gradually. a NOTE Remove stone or other foreign materials pinched in the sprocket, if any. In case of tightening track link Put in grease from fitting @ A caution In case track link adjustment can not be done Track adjuster spring is loaded with strong force and the interior of the cylinder is highly pressurized. Therefore, it is very dangerous to do adjustment, dismantling and the like in- correctly. Such mishandling may cause an accident resulting in injury or death. It is abnormal that the track remains tightened even if the valve (1) is loosened, or that the track is not tightened when greasing. In such a case, never dismantle the tarck or track adjuster. instead, contact nearby workshop for repair promptly. outlet 97Maintenance 3B] Check the Bucket Linkage Clearance — when required (1) Check the bucket clearance “a”. If necessary adjust the shim as follows. (2) Adjustment of bucket linkage (standard bucket) This machine has a bucket adjustment system to take up play in the linkage. When play in the linkage increases, remove shims as explained below. This will allow the bush @ to move to the right and take up the clearance “a” between the bush and the arm boss. (i) Remove bolt @ and plate @ (ii) Remove shims @) according to the clearance ng (iii) Fit plate © to pin © and tighten bolt @. NOTES: Bucket clearance “a” should not be adjusted below 0.5 mm, Pin learance “a” Ty Plate 3) Shim Clearance adjustment —98—Maintenance Bl Toraue check = every 250 hrs. (Initial 50 hrs.) Retightening nuts and bolts The correct torque is essential for the proper fit of assembled parts. The following nuts and bolts should be checked and retightened to the proper torque after the first 50 hrs. of operation, and then rechecked every 250 hrs. or 30 days. This illustration shows the points which require re- tightening, The tightening torque of each bolt is shown in this table. No] lem ote Aeintenes Dia mat | Ory | Toolmm | Nem that) © | Engine nsision e 2 [7 | 7 or Rubber Ataching Bots w | 4 | 2 | 206 an Engine Bracket Ataching Bolts 10 a] 7 | ats ® | 04 Tank Mounting Bats 6 a | 2 | 206 en © | Fun! Tak Mounting Bolts w | 4} 2 | 20 en 3) | Hydra Hose Union }-sn6-12un as | 77 ue hae zune a | ae an Pump Transnistion Avaching Bots | 10 a} wv | 6s Contra Vale Attaching Bolts we | a | 28 | 208 wa ‘Swing Device Artaching Bots 2 | 12] 9 | S20 158) Swing Motor Attaching Bots w | 2] 27 | 28 Go Batery Attaching Bots | 0 2} uv | 05 cat Anaching Bolts 6 a} 24 | 206 en Swing Bearing Ataching Bolts » | 3 | % | sx 6s ‘Track Frame) Sing Bearing Actaching Bolts w | 2 | % | so 6 ‘hin Frame) 4 | Propet Device Ataching Bolts 2 | 2 | 9 | 50 65 48 | Sprocket Attaching Bots 20 | 32) 30 | 539 G5) {9 | Care Roller Attaching Bots we | w | 2% | 265 (an | roacroieavacionsors | 6 | Bf om | am oo ® | sree sons we | gt] 2 | a7 ss | Track gurd Attaching Bolts w | 3 | a | 265 an oie” Fagrerin TT show the ty stings Yor E200L6 NOTE The force of bolt tightening is expressed by torque. For example, the torque of turning the edge of a 1 m long wrench with the force of 12 N will be: 1 m x 12 N = 12. Nem. 99Maintenance @ Retighten engine insulation rubber fixing bolts, Too! + 27 mm Torque: 294 N-m (30 kgf-m) Tool: 24mm Torque: 206 Nem (21 kgf-m) @® Engine bracket mounting bolts Tool: 17mm Torque: 49 N-m (5 kgf-m) @) @ Retighten hydraulic oil and fuel tank fixing bolts, Tool: 24mm Torque: 206 N-m (21 kgf-m) Retighten high-pressure hose unions. Tool : 36mm Torque: 177 N-m (18 kgf-m) Tool: 41mm Torque: 206 N-m (21 kgf-m) —100—Maintenance L -— (6) Retighten pump transmission attaching bolts. Tool : 17mm Torque: 49 Nem (5 kgfm) @ Retighten control valve attaching bolts. Tool: 24mm Torque: 206 Nem (21 kgf-m) ® ® Retighten swing device and motor attaching bolts Tool: 30mm Torque: 539 N-m (55 kgf-m) Tool : 27mm Torque: 294 N-m (30 kgf+m) (10 Retighten battery attaching bolts, Tool : 17mm Torque: 49 N-m (5 kgf-m) 1) Retighten cab attaching bolts. Tool = 24mm Torque: 206 Nem (21 kgf-m) —101—Maintenance @ Retighten swing bearing attaching bolts. (Track Frame) Tool : 30mm Torque: 539 N:m (55 kgf-m) (Main Frame) Tool : 30mm Torque: 510 N-m (52 kgf-m) (® Retighten propelling device attaching bolts. Tool : 30mm Torque: 539 N-m (55 kgf-m) (1M Retighten sprocket attaching bolts Tool : 30mm Torque: 539 Nem (55 kgf-m) (18) Retighten carrier roller attaching bolts. Tool: 24mm Torque: 265 Nem (27 kst-m) —102—