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Hitachi Ex1200-5D Excavator Technical Operator’s Manual (EM18F-EN1-1) – PDF Download
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- Hitachi Ex1200-5D Excavator Technical Operator’s Manual
- Part No:EM18F-EN1-1
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Description
Hitachi Ex1200-5D Excavator Technical Operator’s Manual (EM18F-EN1-1)
File Details:
Hitachi Ex1200-5D Excavator Technical Operator’s Manual
- Manual Language:English
- Pages: 303
- Size: 8.64 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX1200-5D EXCAVATOR TECHNICAL OPERATOR’S MANUAL (EM18F-EN1-1) – PDF DOWNLOAD:
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Description:
Hitachi Ex1200-5D Excavator Technical Operator’s Manual (EM18F-EN1-1)
- Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.
- This standard specification machine can be operated under the following conditions without being modified.
- In case the machine is used under conditions other than described above, consult your nearest Hitachi dealer.
- This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.
- This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.
- Right-hand and left-hand sides are determined by facing in the direction of forward travel.
- Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.
- Warranty is provided as a part of Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty isexplained on the warranty certificate which you should have received from your dealer.
- This warranty provides you the assurance that Hitachi will back its products where defects 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 warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.
- Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.
- Prior to operating this machine in a country other than a country of its intended use, it may be necessary to make modifications to it so that it complies with the local standards (including safety standards) and requirements of that particular country. Please do not operate this machine outside of the country of its intended use until such compliance has been confirmed. Please contact Hitachi Construction Machinery Co., Ltd. or any of our authorized distributor or dealer if you have any questions concerning compliance.
Table Of Contents:
Hitachi Ex1200-5D Excavator Technical Operator’s Manual (EM18F-EN1-1)
EM18F-EN1-1.............................................................. 1 INTRODUCTION......................................................... 2 MACHINE NUMBERS...................................................... 3 CONTENTS............................................................. 6 SAFETY............................................................... 9 SAFETY SIGNS......................................................... 37 COMPONENTS NAME...................................................... 45 COMPONENTS NAME.................................................. 45 GETTING ON / OFF THE MACHINE......................................... 46 GETTING ON / OFF THE MACHINE..................................... 46 OPERATOR’S STATION................................................... 47 EMERGENCY ROPE (Elevated Cab).................................... 47 CAB FEATURES..................................................... 48 MONITOR PANEL.................................................... 49 FUEL GAUGE....................................................... 50 FUEL LEVEL INDICATOR............................................. 50 ALTERNATOR INDICATOR............................................. 50 ENGINE EXHAUST TEMPERATURE INDICATOR............................ 50 HYDRAULIC OIL LEVEL INDICATOR.................................... 51 ENGINE WARNING INDICATOR......................................... 51 C OOLANT LEVEL INDICATOR......................................... 51 ENGINE STOP INDICATOR............................................ 52 AUTO-LUBRICATION INDICATOR....................................... 52 ENGINE OIL LEVEL INDICATOR (WARNING)............................. 52 PUMP TRANSMISSION OIL PRESSURE INDICATOR (WARNING).............. 52 ENGINE OIL PRESSURE INDICATOR.................................... 53 P REHEAT INDICATOR.............................................. 53 DOWNLOAD INDICATOR............................................... 53 OVERHEAT INDICATOR............................................... 54 AIR FILTER RESTRICTION INDICATOR................................. 54 LUBRICATION MODE INDICATOR....................................... 54 DISPLAY.......................................................... 55 AUTO-IDLE INDICATOR.............................................. 55 QUICK IDLE INDICATOR............................................. 55 SWITCH PANEL 1................................................... 56 DISPLAY SELECTION SWITCH......................................... 56 HOUR METER....................................................... 56 TRIP METER 1 AND TRIP METER 2.................................... 57 SET SWITCH....................................................... 58 LUBRICATION MODE SWITCH.......................................... 59 SWITCH PANEL 2................................................... 60 ENGINE CONTROL DIAL.............................................. 60 AUTO-IDLE SWITCH................................................. 61 POWER MODE SWITCH................................................ 61 TRAVEL MODE SWITCH............................................... 62 WORK LIGHT SWITCH................................................ 63 WIPER/WASHER SWITCH.............................................. 64 RIGHT CONSOLE.................................................... 65 KEY SWITCH....................................................... 65 ALU TIMER SWITCH (Auto-Lubrication Timer Switch)................ 65 HEAVY LIFT SWITCH................................................ 66 BOOM MODE SWITCH................................................. 66 AUTO AIR CONDITIONER............................................. 67 CAB HEATER OPERATION............................................. 71 COOLING OPERATION................................................ 71 DEFROSTER OPERATION.............................................. 72 TIPS FOR OPTIMAL AIR CONDITIONER USAGE........................... 73 LEFT CONSOLE..................................................... 75 STEP LIGHT SWITCH................................................ 76 AM/FM RADIO OPERATION............................................ 77 DIGITAL CLOCK SETTING PROCEDURE.................................. 78 REAR CONSOLE..................................................... 79 ENGINE DIAGNOSTIC SWITCH......................................... 79 BUZZER AND BUZZER STOP SWITCH.................................... 80 TRAVEL ALARM STOP SWITCH (Optional).............................. 80 DLU CHECK SWITCH................................................. 80 QUICK IDLE SWITCH................................................ 81 DOWNLOAD INDICATOR............................................... 81 HORN SWITCH...................................................... 81 PILOT CONTROL SHUT-OFF LEVER..................................... 82 CAB LIGHT........................................................ 82 FUSE BOX (Left).................................................. 83 FUSE BOX (Right)................................................. 83 CAB DOOR RELEASE LEVER........................................... 84 OPENING CAB DOOR WINDOW.......................................... 84 EMERGENCY EXIT................................................... 85 HAZARD WARNING LAMP --- LOCATION................................. 85 EXTINGUISHER --- IF EQUIPPED..................................... 85 EMERGENCY EXIT (Elevated Cab).................................... 86 ADJUSTING THE SEAT............................................... 88 ADJUSTING CONSOLE HEIGHT......................................... 89 SEAT BELT........................................................ 90 BREAK-IN............................................................. 91 OBSERVE ENGINE OPERATION CLOSELY................................. 91 EVERY 10 HOURS OR DAILY.......................................... 91 AFTER THE FIRST 50 HOURS......................................... 91 OPERATING THE ENGINE................................................. 93 INSPECT MACHINE DAILY BEFORE STARTING............................ 93 BEFORE STARTING ENGINE........................................... 94 LEVEL CHECK...................................................... 95 STARTING THE ENGINE IN ORDINARY TEMPERATURE..................... 96 STARTING THE ENGINE IN COLD WEATHER.............................. 97 CHECK INSTRUMENTS AFTER STARTING................................. 98 USING BOOSTER BATTERIES.......................................... 99 STOPPING THE ENGINE..............................................101 DRIVING THE MACHINE..................................................103 DRIVE THE MACHINE CAREFULLY......................................103 STEERING THE MACHINE USING PEDALS................................104 STEERING THE MACHINE USING LEVERS................................105 TRAVEL MODE SWITCH...............................................106 T RAVEL ALARM (OPTIONAL)........................................106 TRAVELING........................................................107 OPERATING ON SOFT GROUND.........................................108 RAISE ONE TRACK USING BOOM AND ARM...............................108 TOWING MACHINE A SHORT DISTANCE..................................109 OPERATING IN WATER OR MUD........................................110 PRECAUTIONS FOR TRAVELING ON SLOPES.............................111 PARKING THE MACHINE ON SLOPES....................................112 PARKING THE MACHINE..............................................112 OPERATING THE MACHINE................................................113 CONTROL LEVER (ISO PATTERN BACKHOE)..............................113 CONTROL LEVER (ISO PATTERN LOADING SHOVEL)......................114 BUCKET OPEN-CLOSE PEDALS (LOADING SHOVEL).......................115 CONTROL LEVER (HITACHI PATTERN BACKHOE)..........................116 CONTROL LEVER (HITACHI PATTERN LOADING SHOVEL)..................117 PILOT CONTROL SHUT-OFF LEVER.....................................118 AUTO-IDLE........................................................120 QUICK IDLE.......................................................121 ENGINE SPEED CONTROL.............................................122 POWER MODE.......................................................123 E (ECONOMY) MODE.................................................124 P (POWER) MODE...................................................125 S/P (SUPER POWER) MODE...........................................126 HEAVY LIFT.......................................................127 PRECAUTIONS FOR OPERATIONS.......................................128 OPERATE THE MACHINE SAFELY.......................................129 OPERATING BACKHOE................................................130 GRADING OPERATION................................................130 AVOID ABUSIVE OPERATION..........................................131 OPERATING TIPS...................................................132 SELECT CORRECT TRACK SHOES.......................................132 LOADING SHOVEL OPERATION.........................................133 PROHIBITED OPERATION.............................................133 OBJECT HANDLING --- IF EQUIPPED..................................136 OVERNIGHT STORAGE INSTRUCTIONS...................................137 TRANSPORTING.........................................................139 PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION................139 MAINTENANCE..........................................................147 CORRECT MAINTENANCE AND INSPECTION PROCEDURES...................147 CHECK THE HOUR METER REGULARLY...................................148 USE CORRECT FUELS AND LUBRICANTS.................................148 PREPARE MACHINE FOR MAINTENANCE..................................149 HOOD AND ACCESS COVERS...........................................150 USE ELECTRICAL OUTLET............................................150 CONSTRUCTION OUTLINE.............................................152 HYDRAULIC SYSTEM.................................................153 LOADING SHOVEL...................................................154 BACKHOE..........................................................155 ELECTRICAL CIRCUIT...............................................157 EX1200-5D ELECTRICAL CIRCUIT DIAGRAM.............................159 PERIODIC REPLACEMENT OF PARTS....................................161 MAINTENANCE INTERVAL GUIDE.......................................164 A. GREASING......................................................167 Front Joint Pins.............................................168 Swing Bearing................................................172 Swing Internal Gear..........................................175 Fan Pulley and Tension Pulley................................176 B. ENGINE........................................................176 Engine Oil Level.............................................177 Change Engine Oil............................................177 Replace Engine Oil Filters...................................177 C. TRANSMISSION..................................................179 Pump Transmission............................................180 Swing Reduction Gear.........................................183 Travel Reduction Gear........................................185 D. HYDRAULIC SYSTEM..............................................187 INSPECTION AND MAINTENANCE OF HYDRAULIC EQUIPMENT...........188 Check Hydraulic Oil Level....................................190 Drain Hydraulic Tank Sump....................................191 Change Hydraulic Oil.........................................192 Suction Filter Cleaning......................................195 Replace Drain Filter Element.................................196 Replace Full-Flow Filter.....................................198 Replace Pilot Oil Filter Element.............................200 Check Hoses and Lines........................................202 SERVICE RECOMMENDATIONS FOR HYDRAULIC FITTINGS..............205 E. FUEL SYSTEM...................................................208 Drain Fuel Tank Sump.........................................210 Drain Fuel Filter Sediment...................................211 Replace Fuel Filter..........................................212 Check Fuel Hoses.............................................213 Clean the Fuel Cooler Core...................................215 F. AIR CLEANER...................................................216 Clean the Air Cleaner Outer Element..........................216 Replace the Air Cleaner Outer and Inner Elements............216 G. COOLING SYSTEM................................................218 Check Coolant Level..........................................219 Check DCA4 Concentration in Coolant..........................220 Replace Coolant Filter.......................................228 Check Fan Belt for Wear......................................229 Change Coolant...............................................230 Clean Radiator Core and Oil Cooler Core Radiator Outside....232 H. AIR CONDITIONER...............................................233 Recirculation Air Filter.....................................233 Ventilation Air Filter.......................................234 Check Refrigerant Quantity...................................235 Check Compressor Belt Tension................................236 Clean Condenser Core.........................................236 Check Tightening Torque......................................237 Seasonal Maintenance.........................................238 I. ELECTRICAL SYSTEM.............................................239 REPLACE BATTERIES............................................242 REPLACING FUSES..............................................243 J. MISCELLANEOUS.................................................248 Check Bucket Teeth...........................................249 Change Bucket (Backhoe)......................................254 Check and Replace Seat Belt..................................255 Check Windshield Washer Fluid Level..........................255 Check Track Sag..............................................256 Auto-Lubrication System......................................258 Check Tightening Torque of Bolts and Nuts....................262 Check O-rings in Bucket Joints...............................276 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS...................277 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS...............277 STORAGE..............................................................279 STORING THE MACHINE..............................................279 REMOVING THE MACHINE FROM STORAGE................................280 TROUBLESHOOTING......................................................281 ENGINE...........................................................281 ELECTRICAL SYSTEM................................................286 MODE SELECTION...................................................288 CONTROL LEVERS...................................................289 HYDRAULIC SYSTEM.................................................289 SPECIFICATIONS.......................................................293 SPECIFICATIONS...................................................293 WORKING RANGE (BACKHOE)..........................................295 WORKING RANGE (BE BACKHOE).......................................296 WORKING RANGE (LOADING SHOVEL)...................................297 BACKHOE SHOE TYPES AND APPLICATIONS.............................298 SOUND LEVEL RESULTS (2000/14/EC).................................299 INDEX................................................................301
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