Hitachi Ex1200-5D Excavator Technical Maintenance Manual (KO-235-00) – PDF Download

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Hitachi Ex1200-5D Excavator Technical Maintenance Manual (KO-235-00)

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Hitachi Ex1200-5D Excavator Technical Maintenance Manual (KO-235-00)

• Manual Language:English
• Pages: 175
• Size: 14.2 MB
• Downloadable:Yes
• Format:PDF

HITACHI EX1200-5D EXCAVATOR TECHNICAL MAINTENANCE MANUAL (KO-235-00) – PDF DOWNLOAD:

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Hitachi Ex1200-5D Excavator Technical Maintenance Manual (KO-235-00)

• Buckets attached to hydraulic excavators play a key role in iterative digging-loading-dumping work. Generally speaking, the capacity and mass are set to maximize the capacity and efficiency of the machine. Based on long years of experience and its operational track record, Hitachi markets two main types of buckets: general-use and rock-use buckets.
• The customer can choose between the two buckets according to the target excavator application. It is important that buckets are used in the most effective way. Furthermore, it is inherently difficult to determine the bucket life, but it can be estimated roughly according to two factors: damage resulting from wear, and damage resulting from impact.
• With the latter, a rough estimation of bucket life can be made. However, when it comes to the former, one needs to be careful when making an estimation since weardamage differs greatly from one work site to the next depending on the target-substance (rock type) and digging method. This manual describes the structure of Hitachi buckets, design considerations, and correct protective reinforcement and efficient maintenance methods. We feel that this information will allow you to keep using the bucket for a long time and get the most out of the bucket.

Table Of Contents:

Hitachi Ex1200-5D Excavator Technical Maintenance Manual (KO-235-00)

COVER..........................................................................................................  1
FOREWORD.......................................................................................................  2
HOW TO USE THIS MANUAL.........................................................................................  3
CONTENTS.......................................................................................................  4
	SECTION 01 BUCKET TYPES AND APPLICATIONS...................................................................  5
		1. TYPES OF FRONT ATTACHMENTS AND THEIR USES...........................................................  6
			1.1 Types of Booms and Their Uses..................................................................  6
			1.2 Types of Arms and Their Uses...................................................................  7
			1.3 Types of Buckets and Their Uses................................................................  8
		2. BASIC BUCKET CONSTRUCTION...........................................................................  9
			2.1 Basic Structure of the Buckets................................................................. 10
			2.2 Function of Backhoe Bucket..................................................................... 19
			2.3 Function of Loading Shovel Buckets.............................................................  5
			2.4 Boom-Arm-Bucket combinations................................................................... 29
	SECTION 02 POINTS FOR MAINTENANCE / REINFORCEMENT AND PERIODIC INSPECTION.................................. 34
		3. WHY PERIODIC MAINTENANCE / REINFORCEMENT & REPAIR ARE NEEDED........................................ 35
			3.1 WEAR OF BUCKET STRUCTURE....................................................................... 36
				3.1.1 For what reasons or under what conditions does wear develop?............................. 36
				3.1.2 Notch-wear and deformational-wear........................................................ 37
				3.1.3 Types of rock and the wear of steel...................................................... 38
				3.1.4 Wear conditions and wear-resistant materials............................................. 41
			3.2 POINTS......................................................................................... 42
				3.2.1 Selecting the correct bucket point type for the target material.......................... 42
				3.2.2 Point types and their features........................................................... 43
				3.2.3 Selecting the appropriate point-form..................................................... 45
			3.3 WEAR MAINTENANCE FOR THE BUCKET STRUCTURE (WEAR INSPECTION POINTS)............................. 49
			3.4 WHAT HAPPENS WITHOUT MAINTENANCE / REINFORCEMENT & REPAIR OF THE BUCKET (SPECIFIC EXAMPLES).... 51
				3.4.1 The case of a backhoe.................................................................... 51
				3.4.2 The case of a loading shovel............................................................. 54
				3.4.3 Guidelines for maintenance / reinforcement & repair...................................... 56
			3.5 IF MAINTENANCE / REINFORCEMENT & REPAIR IS AND IS NOT CARRIED OUT.............................. 58
			3.6 EFFECTS OF BUCKET MAINTENANCE / REINFORCEMENT & REPAIR ON THE MACHINE.......................... 59
				3.6.1 Guidelines for the weight of wear-resistant reinforcement material to be added........... 59
				3.6.2 Attention! Do not over-add plates during maintenance / reinforcement & repair work....... 60
		4. CORRECT MAINTENANCE / REINFORCEMENT & REPAIR WORK................................................... 61
			4.1 MAINTENANCE / REINFORCEMENT / REPAIR WELDING................................................... 62
			4.2 MAINTENANCE / REINFORCEMENT / REPAIR INSTRUCTIONS.............................................. 64
				4.2.1 Bucket maintenance / reinforcement / repair.............................................. 64
				4.2.2 Adapter / nose repair instructions....................................................... 78
				4.2.3 Repairing adapters by cladding........................................................... 85
				4.2.4 Nose replacement instructions............................................................ 86
				4.2.5 Integral nose lip repair instructions.................................................... 90
				4.2.6 Lip repair instructions.................................................................. 94
		5. PERPETUAL MAINTENANCE AFTER PUTTING THE MACHINE INTO OPERATION...................................... 96
	SECTION 03 SAFETY.......................................................................................... 97
		FOLLOW SAFETY INSTRUCTIONS............................................................................. 98
		SAFETY PRECAUTIONS FOR MAINTENANCE / REINFORCEMENT WELDING WORK........................................ 98
		PRECAUTIONS FOR WELDING AND HEATING.................................................................... 99
		CAUTIONS TO BE TAKEN WHILE WELDING AND HEATING......................................................... 99
		USE HANDHOLDS AND STEPS................................................................................100
		PRECAUTIONS FOR MACHINE OPERATION......................................................................100
		PRACTICE SAFE MAINTENANCE / REINFORCEMENT WELDING......................................................101
	SECTION 04 DOS AND DON'TS: FUNDAMENTALS....................................................................102
	SECTION 05 DOS AND DON'TS: EXAMPLES........................................................................106
	SECTION 06 TOOLS & AUXILIARY EQUIPMENT.....................................................................111
	SECTION 07 PREHEATING POSTHEATING..........................................................................114
		1. Preheating..........................................................................................115
		2. Interpass temperature...............................................................................115
		3. Warming Up..........................................................................................116
		4. Postheating.........................................................................................116
		5. Selection of Preheating Temperature.................................................................117
		6. Preheating Method...................................................................................118
		7. Temperature Checking Method.........................................................................119
	SECTION 08 WELDING.........................................................................................121
		1. Weld Steel..........................................................................................122
		2. Electrode...........................................................................................123
		3. Drying of Electrode.................................................................................126
		4. Cleaning of Weld Section Before Welding.............................................................127
		5. Welding Current.....................................................................................127
		6. Welding Speed.......................................................................................128
		7. Tack Welding........................................................................................128
		8. Temporary Welding of Supplementary Parts............................................................132
		9. Weld Distortion.....................................................................................133
		10. Types of Weld Defects..............................................................................135
		11. Major Types of Weld Defects and Their Causes.......................................................136
		12. Visual Inspection Standards for Weld Joints........................................................138
		13. Removal and Repair of Weld Defects.................................................................139
		14. Inspection After Repairing Weld Defects............................................................140
		15. Precautions for Semi-Automatic Welding.............................................................140
	SECTION 09 MAINTENANCE / REINFORCEMENT WELDING.............................................................141
		1. Precautions for Maintenance / Reinforcement Welding.................................................142
		2. Preparation for Maintenance / Reinforcement Welding.................................................142
		3. Precautions for Installation of Reinforcing Plates..................................................144
		4. Examples of Reinforcement...........................................................................145
	SECTION 10 FINISHING.......................................................................................146
		1. Importance of Finishing.............................................................................147
		2. Kinds of Grinders...................................................................................147
		3. Proper Grinder Use..................................................................................150
		4. Direction of Grinding...............................................................................151
		5. Finishing Joints between New and Old Beads..........................................................151
	SECTION 11 APPENDIX........................................................................................152
		1. Nominal Stress and Stress Concentration.............................................................153
		2. Cracks at Weld Joints...............................................................................154
		3. Fatigue Strength and Importance of Grind Finishing..................................................155
		4. Mechanical Properties of Weld Steel.................................................................156
		5. Specificaitons of Shield Arc Electrodes for Mild Steel..............................................157
		6. Specifications of Shield Arc Electrodes for High Tensile Steel......................................158
		7. Estimation Formula of Preheat Temperature...........................................................159
		8. Weld Terms..........................................................................................160
		9. Maintenance of other bucket-related parts...........................................................168

Please Note:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]