Manual de Ensamble 1200-6

KO-356-00
ASSEMBLY
PROCEDURE
MANUAL
Foreword
Assembly work is the final touch that gives the machine life. The quality of a machine's
assembly affects its operative performance and service life of the machine.
Because a machine's value is determined by its assembly, those who do this work are
required to have sufficient know-how about assembly.
This manual basically contains assembly know-how such as methods and useful hints for
assembling the EX1200-6 Hydraulic Excavator. Please read this manual carefully and try to
keep it for reference before you engage in assembly or while you work.
This manual is a practical compilation of the following three viewpoints: "the improvement
of work safety", "the improvement of efficiency" and "the enhancement of product quality."
1) Safety: Some hints and information for safe work are provided, such as the
weight of the parts, their lifting points when raised with wire ropes and
their handling procedures.
Work safety is attained with this manual.
2) Quality: Procedures and hints are described for correct machine assembly. They
include the part numbers, tightening torque values of bolts, etc. Correct
assembly is essential to provide the machine with a longer service life at
maximum performance.
3) Efficiency: Tool jigs, the facilities necessary to do the work and the preparation
needed for each work stage are introduced to assure speedy and
effective completion.
We hope this manual will be helpful to you in assembling the machine without a hitch.
i
CONTENTS
Page
1. Precautions ………………………………………………………………………………………………………………1
1-1. Safety precautions for servicemen ……………………………………………………………………………1
1-2. How to use a power wrench ……………………………………………………………………………………14
1-3. Work precautions ………………………………………………………………………………………………17
2. Workers plan (Loader front) …………………………………………………………………………………………27
2'. Workers plan (Backhoe front) ………………………………………………………………………………………28
2-1. Transportation (Loader front) …………………………………………………………………………………29
2-1'. Transportation (Backhoe front) ………………………………………………………………………………30
3. Parts check ……………………………………………………………………………………………………………38
3-1. Check ……………………………………………………………………………………………………………38
4. Preparations (Loader front) …………………………………………………………………………………………40
5. Preparations (Backhoe front) ………………………………………………………………………………………42
6. Machines, apparatus, tools, and materials necessary for assembly ………………………………………45
7. Assembly of upperstructure ………………………………………………………………………………………51
7-1. Preparations ……………………………………………………………………………………………………51
7-2. Connection of upperstructure and side frames ………………………………………………………………55
7-3. Connection of travel motor hoses ……………………………………………………………………………65
7-4. Assembly of cab & handrail, step and ladder etc.……………………………………………………………67
7-5. Installation of counterweight, camera and rear lamps ………………………………………………………83
7-6. Greasing of swing bearing ……………………………………………………………………………………87
7-7. Vacuuming (air purge work) & charging of refrigerant ………………………………………………………89
7-8. Final check of superstructure …………………………………………………………………………………109
7-9. Releasing the air from the main pumps ……………………………………………………………………113
7-10. Trial operation of superstructure ……………………………………………………………………………115
7-11. Disassembly procedures for shipment ………………………………………………………………………116
8. Mounting procedures for loader front ……………………………………………………………………………123
8-1. Preparation ……………………………………………………………………………………………………123
8-2. Mounting of loader front ………………………………………………………………………………………131
8-3. Mounting of bucket ……………………………………………………………………………………………141
8-4. Adjustment of track link tension ………………………………………………………………………………151
8-5. Final trial operation check ……………………………………………………………………………………153
9. Mounting procedures for backhoe front…………………………………………………………………………161
9-1. Preparation ……………………………………………………………………………………………………161
9-2. Mounting of backhoe boom …………………………………………………………………………………171
9-3. Mounting of arm ………………………………………………………………………………………………183
9-4. Mounting of bucket ……………………………………………………………………………………………193
9-5. Adjustment of track link tension ………………………………………………………………………………201
9-6. Final trial operation check ……………………………………………………………………………………203
10. Checks after completing the assembly …………………………………………………………………………213
11. Checking machine performance …………………………………………………………………………………215
ii
EX1200-6 Loader front
Front attachment
Arm cylinder Level cylinder Boom cylinder

Arm
Boom
Bucket cylinder Cab Upp
erstr
uctu
re
Swing drive
Bucket
Fuel tank Oil cooler
Engine
Radiator
iii
Track link assembly
Front idler
Counterweight
Track spring
Un Pump
der
car
riag Lower roller
e
Upper roller
Final drive
EX1200-6 Backhoe front
Front attachment
Arm Arm cylinder

Bucket cylinder Boom cylinder
Upperstructure
Boom
Cab Swing drive

Bucket
Fuel tank Oil cooler
Engine
Radiator
iv
Track link assembly
Front idler Counterweight
Track spring
Lower roller Pump
Upper roller
Undercarriage
Final drive
EX1200-6 Assembly Process Chart
LOADER FRONT
v
Weight: 114 000 kg (250 800 lb)
EX1200-6 Assembly Process Chart
BACKHOE FRONT
vi
Weight: 111 000 kg (244 200 lb) Standard
Weight: 112 000 kg (246 400 lb) BE
1. Precautions
1-1 Safety precautions for servicemen
1 RECOGNIZE SAFETY INFORMATION

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

practices.
Fig. 1-1
2 UNDERSTAND SIGNAL WORDS

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

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

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

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

etc. for assembly.
Fig. 1-2
DANGER and WARNING safety signs are located near
specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety items in
this manual.
To avoid confusing machine protection with personal

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

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

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

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

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

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

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

appropriate to the job.
You may need:

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

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

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

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

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

dismount a moving machine.
Fig. 1-11
Be careful of slippery conditions on platforms, steps,
and handrails when getting off the machine.
4
12 FUEL SAFETY AND FLAMMABLE
MATERIALS
a) Never smoke while refueling or handling flammable
materials.
b) Shut the engine off while refueling.
c) Exercise caution when refueling while the engine is
still hot.
d) Do not clean parts using opened cans of gasoline
or diesel fuel. Use good, commercial, non-
flammable solvents.
Fig. 1-12
13 PREVENT BATTERY EXPLOSIONS

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

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

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

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

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

care to protect your hands and body from high-
pressure fluids. Wear a face shield or safety goggles
for eye protection.
Fig. 1-14-1
• If an accident occurs, see a doctor familiar with this
type of injury immediately.
Any fluid injected into the skin must be surgically
removed within a few hours, or gangrene may result.
Fig. 1-14-2 Fig. 1-14-3 Fig. 1-14-4
15 CHECK EQUIPMENT SAFETY

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

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

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

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

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

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

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

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

engine running, do not leave the machine unattended.
Boom
If the machine must be raised, maintain a 90 to 110˚

Arm
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work. Never work under a machine raised by the boom.
90 to
110°
Inspect certain parts periodically, and repair or replace
as necessary. Refer to the relevant section of the
Operation Manual.
Fig. 1-19-2
Keep all parts in good condition and properly installed.
Fix any damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil or debris.
Disconnect the battery ground cable (-) before making

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

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

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

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

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

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

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

from the working area when striking any object.
Fig. 1-22
9
23 PREVENT AGAINST FLYING PARTS
Grease in the track adjuster is under high pressure.
Do not attempt to remove a GREASE FITTING or
VALVE ASSEMBLY.
Be sure to keep your body and face away from any
valve, as pieces may fly off.
The travel reduction gears are under pressure.
So as to avoid injury from flying parts, be sure to keep
your body and face away from the AIR RELEASE
PLUG.
GEAR OIL is hot. Wait for the GEAR OIL to cool, then Fig. 1-23
gradually loosen the AIR RELEASE PLUG to release

pressure.
24 PREVENT BURNS
Hot spraying fluids:
• After operation, the engine coolant is hot and under
pressure. Also, hot water or steam is contained in the
engine, radiator and heater lines.
Prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop
position.
Allow all pressure to release before removing the
Fig. 1-24-1
cap.
• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.
Hot fluids and surfaces:

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

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

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

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

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

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

SYSTEM SAFELY
Refer to the outside of the freon container for proper
handling procedures when servicing the air
conditioning system.
Use a recovery and recycling system to avoid venting
freon into the atmosphere.
Never let the freon stream make contact with your skin.
Severe frost burns will result.
28 HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paint, and adhesives.
Fig. 1-27
11
29 HANDLE POWER WRENCHES
CORRECTLY
Misuse of power wrenches (part nos. 4289389 and
4298388) may lead to their breakage or personal injury.
Please use power wrenches correctly and in
accordance with this manual.
1 For your safety, do not enter into the turning circle

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

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

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

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

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

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

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

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

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

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

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

(N.m)
(1372)
(1078)
In selecting a power wrench, give due consideration of the

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

No. Descriptions
(mm) (mm) N·m kgf·m lbf·ft
7
1− 16 −12 UNF 41 210 21 152
1 ORS fittings for hydraulic hoses and piping
11
1− 16 −12 UNF 50 350 35 255
2 Cab mounting bolt 16 24 210 21 152
3 Side frame mounting bolt 42 65 4000 400 2890
4 Counterweight mounting bolt 45 65 4000 400 2890
Front pin lock bolt (Loading shovel)
5 A. Front pin lock bolt 20 30 400 40 290
B. Bucket pin lock bolt 20 *17 400 40 290
C. Bucket pin lock bolt 16 24 270 27 195
D. Bucket pin lock bolt 12 19 90 9 65
Front pin lock bolt (Backhoe)

6 A. Front pin lock bolt 20 30 400 40 290
B. Stopper bolt 20 30 400 40 290
Note: *Hexagonal socket wrench
16
1-3 Work precautions
1 APPLYING LUBRICANT
1 Be sure to apply a suitable lubricant to mounting
bolts before tightening. Use lubricant made by
mixing white zinc jelly and spindle oil in 1: 1
White zinc jelly
proportions.
Spindle oil
In the case that these materials are not available,
make up the lubricant from materials of the same
composition:
1:1
Material Composition
White zinc jelly Composition list given on page 26
Spindle oil Composition list given on page 26
2 Lubricant should be applied to both the bolt and
spacer, in the positions marked ＊ in the diagram
Lubricant
below.
Spacer
Bolt
Fig. 1-50
＊＊＊＊ Base
Face area Face area Thread of the head
Fig. 1-51
2 HANDLING SEALS
High Tack Adhesive/
1 Remove the seal fitted to the ports and pipes of Sealant #98D
hydraulic components just before assembly, to
prevent the ingress of dust.
2 Oil will come out when removing the seals from Fig. 1-52
the hydraulic ports. Collect it with a suitable oil

container.
3 Lightly apply High Tack Adhesive/Sealant #98D to
the O-ring before hose connection.
Note:
Obtain high tack adhesive/sealant #98D through
the manufacturer detailed on page 26.
Fig. 1-53
3 CONNECTING HOSES.
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors.
3 When connecting hoses, do not twist them or their Battery
service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
CAUTION:
Hydraulic ports are sealed with plugs on shipment from
the factory. On removal of these plugs, hydraulic oil will
escape due to the internal hydraulic pressure built up
through transportation, etc.
4 POST-WIRING
Be sure to remove the battery cables from the
grounded (-) battery clamp before commencing electric
wiring.
Fig. 1-54
This will help avoid short circuits during electric wiring
Remove cables here
work.
17
5 TIGHTENING LARGE-DIAMETER BOLTS
DURING ASSEMBLY.
1 It is vital that large-diameter bolts be tightened to
the specified tightening torque during assembly. If
torque specifications are not followed, the
operation of the machine will be affected, with
machine failure, lowering of functionality and
shortening of machine life potentially resulting. Be
careful, therefore, to note the correct tightening
torque at each stage of assembly.
This manual describes use of a power wrench to Fig. 1-55
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
2 Be sure to tighten each bolt to the specified torque

using a torque wrench, power wrench, or hydraulic
wrench.
Torque wrench
1) After tightening a bolt to the specified torque,
Fig. 1-56
mark the alignment of the bolt head, spacer and
bolted part. (See Fig. 1-55.)
2) Use only genuine Hitachi bolts.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) If a bolt is too short, you will not be able to be
tighten it sufficiently to secure the parts, possibly
resulting in a serious accident. Pin
Moly coat spray
Fig. 1-57
6 NOTES ON INSERTING PINS WHEN
AFFIXING THE FRONT-END ATTACHMENT.
1 When attaching the front-end attachment,
thoroughly clean away the anticorrosive applied to
the pins and pin holes before inserting the pins,
Pin
then regrease them and spray them with Moly
coat.
2 Be sure to check the alignment of pin holes when
joining parts. Do not use unreasonable force to
insert pins, and attempt to insert all pins manually.
If this is insufficient, use a medium-sized hammer
to ease the pin in place.
The use of forklift prongs to force in pins is
Fig. 1-58
absolutely forbidden. Any other unreasonable
force can lead to a pin being misformed and
rendered unusable, and should be avoided.
(Fig. 1-58)
7 APPLYING SEALING TAPE.

Wrap sealing tape around the bolt in the opposite
direction to the thread direction.
Do not cover the first two threads, as indicated in Fig.
1-59. Fig. 1-59
18
8 PRECAUTIONS FOR CONNECTING THE PILOT HOSES
Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying
attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants
may cause the pilot valve to malfunction.
Plug
Plug
Step 1 The ends of both the valve and hose to be

connected will be sealed with plugs.
Detail A
Fig. 1-60
Adaptor
Step 2 1) Remove the plugs. Fitting
2) Thoroughly clean the hose fitting and Remove

adaptor, then connect them, taking care the plugs
to prevent the ingression of any

contaminants. Detail B
Fig. 1-61
Adaptor
Step 3
Connect the adaptor and hose fitting. Fitting
Notes:
i) When connecting hoses, do not twist
them, or their service life will be
shortened.
ii) Connect the hoses so as to avoid Detail C
contact with other parts. Fig. 1-62
iii) Make sure that no dust has adhered to

the seat face of the hoses.
iv) Be careful to not damage the joining
surfaces of the hoses.
19
9 Standards for Hydraulic Joint Work
A ORS joint
Work procedure
1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!!
Check for dirt and scars
Adapter Hose, union part
O-ring Fig. 1-63
2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand
98D (Loctite, Ltd) to the screw part of the hose union.
Notes:
i) Remember to handle the O-ring with your bare hands!!
ii) Press the entire O-ring with your fingers and install it properly!!
iii) Apply the bond uniformly to the groove. Do not overapply!! (Otherwise, the bond will seep into the hydraulic
circuit, causing a breakdown.)
Handle the O-ring with your bare hands!
Apply spray grease here. Fig. 1-64
3 Screw the hose and union into the adapter.
Notes:
i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the
hose horizontal to each other to keep them immobile!!
ii) Tighten the union nut fully with your hands!!
iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will
not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality,
loosen the union nut and make sure to verify the O-ring!!
Tighten the union nut fully with your hands
Fig. 1-65
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly!!
• Use a specified torque wrench!!
Note:
After the work, carry out a check using a white pen!!
20
B Union joint
Work procedure
1 Check that the adapter and hose union seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!!
Adapter seat surfaces Hose union seat surface
Fig. 1-66
Fig. 1-67
Apply spray grease here
2 Apply spray grease to the screw parts of the hose and union.
Note:
Do not overapply.
(When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil
leak.)
3 Screw the hose into the adapter.
Note:
Tighten fully using your hands!!
(If there are no scars on the thread, you will be able to screw it fully with your hands.)
Tighten the union nut fully with

your hands
Fig. 1-68
4 Tightening the union

• To tighten the union, use a spanner-style torque wrench and control the torque properly!!
• Use a specified torque wrench!!
Notes:
i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it!!
ii) After the work, carry out a check using a white pen!!
21
C Split flange joint
Work procedure
1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.
Notes:
i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts!!
ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt!!
Check for scars and dirt Fig. 1-69
O-ring Hose, flange
2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D
(Loctite, Ltd).
Notes:
i) Remember to handle the O-ring with your bare hands!!
ii) Apply the bond uniformly to the groove. Do not overapply!!
(Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.)
iii) Press the entire O-ring with your fingers and install it properly!!
Handle the O-ring with your bare

hands. Do not overapply the bond. Fig. 1-70
3 Installing the split flange

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

about half its length.
Pay attention to
the O-ring
Fig. 1-71 Fig. 1-72
Split flange Socket bolts
22
3) After setting the hose, install the other split flange.
Notes:
i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-ring
may fall off!!
ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.
Install other split flange

If the bolt has not been
screwed in adequately,
the instability of the hose
seat surface will increase,
causing the O-ring to fall
Fig. 1-73 off
Fig. 1-74
4 Tightening the socket bolt

1) Temporary tightening, hose angle adjustment 2) Tightening the bolts
• Make sure to tighten the bolts in the correct • Tighten the bolts using a crisscross
order to avoid lopsided tightening. sequence in the same way as for temporary
• The bolts should be tightened using a tightening.
crisscross sequence. • Be careful not to tighten the bolts lopsidedly.
• The hose should still have movement even • Be careful not to overtighten the bolts with
after the bolts have been tightened. an impact wrench.
• Adjust the hose angle.
3) Checking the torque
1 4 • Use a torque wrench to check that the bolts
are properly tightened.
• Check the bolts in the same crisscross
Bolt tightening sequence sequence as for tightening.
• After the work, carry out a check using a
white pen.
3 2
Fig. 1-75
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-76 Fig. 1-77
23
10 AFFIXING RUBBER BOOTS
Note:
DRC connector rubber boot handling precautions
• Rubber boots should be fitted NIHON-DEUTSCH

LIMITED-made DRC series connectors (24, 40, 70
poles), attached to excavator wiring joints to prevent
water and dust from entering into the connector. Receptacle plug
Rubber boots
• These rubber boots are supplied in a plastic bag
together with the connectors during shipment, and
should be stored similarly during disassembly.
However, they may be lost, become removed or
flinched during field assembly.
• To prevent this problem, new connectors and rubber

boots are designed to stick together so that they do
not cone apart easily.
• Securely attach the rubber boot to the male plug

Rubber boots
connector before assembly, then connect the plug
and receptacle terminals. Take care that the rubber Fig. 1-78
boot is not out of place or pinched during connection.
Note:
Tighten the DRC connector screw to the specified
torque.
Note:
A gap should be provided here after tightening
the screw.
Recommended torque:
=2.82±0.25 [N･m]
=28.8±2.88 [kgf･cm]
=25±2.5 [in･lbs]
Receptacle
Plug
To fit the connector smoothly, tighten the screw

while shaking the plug and connector.
Wire seal
Note:
Rubber boot
Fig. 1-79 Too weak tightening torque can result in poor
water resistance. Too strong tightening torque
Note: can cause the interface seal to be crushed and
Check that the plug and receptacle are parallel to break.
each other before and after tightening the screw.
24
11 ADJUSTING LIFTING ANGLE
Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever
block) connecting the wire ropes, the lifted angle of the
load can easily be adjusted.
Wire rope
L'
Wire rope
L
Chain block
(Lever block)
Chain block
Wire rope
Lever block
Fig. 1-80
Work
Example
The angle of the workpiece in Fig. 1-80 can be
adjusted using chain blocks A .
Workpiece
Chain block
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-81
25
12 FOR REFERENCE
1 Ingredients of the white zinc jelly and spindle oil.
White zinc jelly
This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil.
Ingredients: Extender pigment (calcium carbonate): 84.0%
Color pigment (titanium oxide): 0.5%
Fatty oil (polymerized oil): 14.0%
Solvent (mineral turpentine): 1.5%
Spindle oil
Physical and chemical properties of this oil are as follows. (grade C machine oil)
Appearance: Light brown
Flash point (COC): Above 160°C (320°F)
Density: 0.89 ~ 0.95 g/cm3
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
2 Purchase high tack adhesive/sealant #98D from the following company:

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

Read the operation manual and this assembly
procedure manual thoroughly to familiarize yourself
with the work procedure.
Fig. 82
26
2. Workers plan (Loader front)
This plan varies depending on jobsite environment, working conditions, assembly facilities, tools, and worker’s skill.
Days 1
day
2
day
Weather fine
40 t×1 day
Cranes
(With operator and assistant)
40 ton nes 40 t×1.5 day
(44 US tons)
1 unit×0.5 day
Scaffolding
Tool check
Unloading
Unpacking major component

PREPARATION
parts
Checking parts
Cleaning parts
Assembly of side frame and

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

ASSEMBLY
Assembly of counterweight
Mounting of bucket
· Greasing
· Refrigerant (gas) quantity
· Track link tension
Adjusting OPERATION
Repainting
Complete assembly check
27
2'. Workers plan (Backhoe front)
This plan varies depending on jobsite environment, working conditions, assembly facilities, tools, and worker’s skill.
Days 1
day
2
day
Weather fine
40 t×1 day
Cranes
(With operator and assistant)
40 ton nes 40 t×1.5 day
(44 US tons)
1 unit×0.5 day
Scaffolding
Tool check
Unloading
Unpacking major component

PREPARATION
parts
Checking parts
Cleaning parts
Assembly of side frame and

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

ASSEMBLY
Assembly of counterweight
Mounting of bucket
· Greasing
· Refrigerant (gas) quantity
· Track link tension
Adjusting OPERATION
Repainting
Complete assembly check
28
2-1 Transportation (Loader front)
3
4
3
Example: Loader front (Unit: metric ton)
1 2 3 4 5
· Boom & Arm
Cab assembly
Side frame assembly
Upperstructure CounterWeight Handrails,
(Left & Right) · Bucket assembly
ladders, step
· Boom cylinder×2
and etc.
35-tonne 35t
trailer
Trailers and trucks
30-tonne 30t 30t

trailer
20-tonne 20t
trailer
15-tonne 15t
truck
29
2-1' Transportation (Backhoe front)
3 4
Example: Backhoe front (Unit: metric ton)
1 2 3 4 5
· Boom assembly Handrails,

Side frame
Upperstructure · Arm assembly CounterWeight ladders, step
(Left & Right) · Bucket assembly and etc.
· Boom cylinder×2
35-tonne 35t
trailer
Trailers and trucks
30-tonne 30t 30t

trailer
20-tonne 20t
trailer
15-tonne 15t
truck
30
TRANSPORTING
PACKING DIMENSIONS AND WEIGHTS FOR TRANSPORTATION
MASE MACHINE
Base Machine (Low-cab)
Backhoe
Weight : 35 000 kg (77 000 lb)
Width : 3 500 mm (11' 9")
Base Machine (High-cab) Cab

Loading shovel Weight : 640 kg (1 408 lb)
Weight : 35 000 kg (77 000 lb)
Width : 3 500 mm (11' 9") Width : 1 213 mm (3' 12")
Counterweight Washer and Bolt~8 Upper duct assembly Seat assembly

Weight : 17 500 kg (38 500 lb) Weight : 8 kg (18 lb) Weight : 3 kg (7 lb) Weight : 44 kg (97 lb)
φ95
30
588
Lower duct assembly

Weight : 2 kg (4 lb)
28
Width : 700 mm (2' 4")
Width : 3 450 mm (11' 4")
31
TRANSPORTATION
UNDERCARRIAGE
Side frame (L) Washer and Bolt~52
Side frame (R) Weight : 5 kg (11 lb)
STD track Full track

guard guard
700G shoe
900G shoe
Ladder~2 Ladder~2
700 mm shoe-use 900 mm shoe-use
Weight : 20 kg (44 lb) Weight : 25 kg (55 lb)
OR
Width : 302 mm (12") Width : 449 mm (1' 6")
Step~2 Cover (R)/Cover (L)

Step next to side frame
~S/No. 1 103 S/No. 1 104~
Width : 90 mm (4") Width : 310 mm (1' 02") Width : 258 mm (10")
32
TRANSPORTATION
LEFT SIDE OF BASE MACHINE
Low-cab parts
Fender Bolt assembly~6
Fender next to the cab
(Washer 4114405)
(Washer, spring A590916)
(Bolt J901680)
Assembly bolt for
installing the fender
next to the cab - 6
Width : 1 041 mm (3' 5")
Fender Step Ladder

Fender next to the hydraulic Weight : 19 kg (42 lb) Weight : 252 kg (554 lb)
oil tank - for standard
Parts to be used for both the high-cab and low-cab
Width : 110 mm (4")

Width : 795 mm (2' 7")
Chain Width : 650 mm (2' 2")
OR Weight : 0.5 kg (1 lb)
Fender Fender
Fender next to the hydraulic oil tank Weight : 160 kg (352 lb)
- when the side ladder is being used
Step
Width : 795 mm (2' 7") Width : 169 mm (7") Width : 644 mm (2' 1")
High-cab parts
Fender Bolt assembly~12 Step
Fender next to the cab Weight : 126 kg (277 lb)
(Washer 4114405)
(Bolt J901680)
Assembly bolt for
next to the cab - 12
Width : 1 041 mm (3' 5") Width : 1 041 mm (3' 5")
33
TRANSPORTATION
RIGHT SIDE OF BASE MACHINE
Fender Handrail Handrail
Weight : 180 kg (396 lb) Weight : 18 kg (40 lb) Weight : 23 kg (51 lb)
Width : 834 mm (2' 9") Width : 192 mm (8") Width : 587 mm (1' 11")
Step Bolt assembly~6 Handrail

(Washer 4114405)
(Bolt J901655)
Assembly bolt for
next to the battery box - 6
Width : 50 mm (2") Width : 50 mm (2")
Duct assembly Bolt assembly~8 Duct assembly

Duct assembly in front of radiator Duct assembly in front of oil cooler
(Washer, plain 4338575)
(Bolt J901402)
Duct mounting
bolt, assembly - 8
Bolt assembly~8
(Bolt, sems J281225)
Duct assembly hinge mounting

sems bolt - 8
Width : 80 mm (3") Width : 80 mm (3")
34
TRANSPORTATION
BASE MACHINE
Muffler cover Exhaust pipe Gasket
Width : 1 390 mm (4' 7")
Mirror assembly Mirror assembly

Weight : 2.4 kg (5.3 lb) Weight : 2.2 kg (4.8 lb)
Width : 50 mm (2") Width : 50 mm (2")
Camera Antenna Wiper assembly Head lamp~2

Weight : 2.5 kg (5.5 lb) Weight : 0.2 kg (0.4 lb) Weight : 0.6 kg (1.3 lb) Weight : 0.8 kg (1.8 lb)
Lamp assembly Rear light~2 Bracket~2 Bracket~2

Weight : 1.0 kg (2.2 lb) Weight : 0.5 kg (1.1 lb) Weight : 0.22 kg (0.5 lb) Weight : 1.0 kg (2.2 lb)
35
TRANSPORTATION
LOADING SHOVEL ATTACHMENT
Loader front
Weight : 15 000 kg (33 000 lb)
Width : 1 490 mm (4' 11")
Loading Shovel Bucket
Boom cylinder~2
Weight : 1 170 kg (2 574 lb)
Width : 356 mm (1' 2")
Clamp assembly Clamp assembly Clamp assembly

Weight : 14 kg (31 lb) Weight : 14 kg (31 lb) Weight : 10 kg (22 lb)
Width : 82 mm (3") Width : 82 mm (3") Width : 82 mm (3")
36
TRANSPORTATION
BACKHOE ATTACHMENT
Boom
Arm
Boom cylinder~2 Clamp assembly Clamp assembly

Weight : 1 130 kg (2 586 lb) Weight : 10 kg (22 lb) Weight : 10 kg (22 lb)
Width : 356 mm (1' 2") Width : 65 mm (3") Width : 65 mm (3")
Backhoe Bucket
37
3. Parts check
3-1 Check
1 Unpack the major component parts.
2 Check their quantity against that shown on the packing

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

If there are any missing or damaged parts, take
pictures of the damage and then contact Hitachi or your
Hitachi distributor as soon as possible.
Fig. 3-1
38
NOTES
39
4. Preparations (Loader front)
1 Work site: Select a place where the ground is firm 3 Cranes: Prepare two 40 tonne (44 US ton) cranes.
and flat.
2 Space: Secure a space of 13 m (43 ft) × 23 m (75 4 Arrangement of major components: See Figs. 4-1,
ft) or more. 4-2 and 4-3 below.
Weight Crane
1 Basic machine assembly 35 000 kg ( 77 000 lb) 12 A

2 Cab 640 kg ( 1 410 lb) 13 B
3 Fenders, handrails and ladders 1 170 kg ( 2 575 lb)
4 Side cover (radiator) 89 kg ( 196 lb)
5 Side cover (oil cooler) 83 kg ( 183 lb)
Wt (kg)/lb
6 Side frame assembly (left) STD track

guard
Full track
guard
15 200 kg 15 700 kg
7 Side frame assembly (right) 700G Shoe
(33 440 lb) (34 540 lb)
15 900 kg
900G Shoe −−−
(34 980 lb)
8 Counterweight 17 500 kg ( 38 500 lb)

9 Boom and arm assembly 15 300 kg ( 33 660 lb)
10 Boom cylinders 1 170 kg ( 2 575 Ib)×2
11 Bucket assembly For 5.9 m3 9 780 kg ( 21 515 Ib)
For 6.5 m3 9 200 kg ( 20 240 Ib)
11 12
7
9 1 8
2
3 -a
6
3 -c
3 -b
4 5
13
10
Fig. 4-1
40
LOADING SHOVEL
(17'3")
5 250
15 400
(50'6")
Weight: 114 000 kg (250 800 lb) Fig. 4-3
Width: 5 130 mm (16'10")
Fig. 4-2
41
5. Preparations (Backhoe front)
1 Work site: Select a place where the ground is firm 3 Cranes: Prepare two 40 tonne (44 US ton) cranes.
and flat.
2 Space: Secure a space of 13 m (43 ft) × 23 m (75 4 Arrangement of major components: See Figs. 5-1,
ft) or more. 5-2 and 5-3 below.
Weight Crane
1 Basic machine assembly 35 000 kg ( 77 000 lb) 12 A

2 Fenders,handrails and ladders 1 260 kg ( 2 770 lb) 13 B
3 Side cover (radiator) 89 kg ( 196 lb)
4 Side cover (oil cooler) 83 kg ( 183 lb)
Wt (kg)/lb
STD track Full track

5 Side frame assembly (left) guard guard
15 200 kg 15 700 kg
6 Side frame assembly (right) 700G shoe
(33 440 lb) (34 540 lb)
15 900 kg
900G shoe −−−
(34 980 lb)
7 Counterweight 17 500 kg ( 38 500 lb)

8 Boom assembly For standard boom 12 500 kg ( 27 500 lb)
For BE boom 11 500 kg ( 25 300 lb)
9 Boom cylinders 1 130 kg ( 2 485 lb) ×2
10 Arm assembly For standard boom 6 450 kg ( 14 255 Ib)
For BE boom 6 480 kg ( 14 255 lb)
11 Bucket assembly For 5.2 m3 4 910 kg ( 10 800 Ib)
For 6.7 m3 6 650 kg ( 14 630 lb)
12
11 6
8 1 7
10
2 -a
5
2 -c
2 -b
3 4
13
9
Fig. 5-1
42
Unit: mm (ft.in) Unit: kg (lb)
A B Width Weight
16 170 mm 5 720 mm 5 470 mm 111 000 kg

EX1200-6 STD. (53' 1") (18' 9") (17' 11") (244 200 lb)
14 620 mm 6 400 mm 5 470 mm 112 000 kg

EX1200-6 BE-front
(47' 12") (20' 12") (17' 11") (246 400 lb)
BACKHOE
A
Fig. 5-3
Fig. 5-2
43
NOTES
44
6. Machines, apparatus, tools, and materials necessary for assembly
Listed below are the machines, apparatuses tools and materials required for assembling the EX1200-6 hydraulic
excavator.
1 Cranes
Two cranes of 40 tonnes (44 US tons)
2 Wire ropes
8 mmø × 3 000 mm (L) - 4 pcs.
(0.3 in) (117 in)
8 mmø × 5 000 mm (L) - 4 pcs.
(0.3 in) (195 in)
10 mmø × 2 000 mm (L) - 2 pcs.
(0.4 in) (78 in)
10 mmø × 3 000 mm (L) - 4 pcs.
(0.4 in) (117 in)
10 mmø × 5 000 mm (L) - 2 pcs.
(0.4 in) (195 in)
22 mmø × 3 000 mm (L) - 4 pcs.
(0.85 in) (117 in)
22 mmø × 10 000 mm (L) - 2 pcs.
(0.85 in) (390 in)
26 mmø × 2 000 mm (L) - 2 pcs.
(1.0 in) (78 in)
26 mmø × 3 000 mm (L) - 2 pcs.
(1.0 in) (117 in)
26 mmø × 8 000 mm (L) - 3 pcs.
(1.0 in) (312 in)
36 mmø × 8 000 mm (L) - 1 pc.
(1.4 in) (312 in)
36 mmø × 10 000 mm (L) - 1 pc.
(1.4 in) (390 in)
3 Nylon sling belts

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

For 2-ton load - 2 pcs. For 2-ton load - 2 pcs. Lever blocks
For 10-ton load - 1 pc. Chain blocks
Note:
There are some methods of centering the work by
the chain block or lever block.
Refer to 11 on page 25 as an example.
45
6 Wooden blocks
1 200 mm (L) × 800 mm (W) × 1 000 mm (H) - 2 pcs. 1 000 mm (L) × 500 mm (W) × 800 mm (H) - 2 pcs.
(49 in) (30 in) (40 in) (40 in) (20 in) (30 in)
1 500 mm (L) × 300 mm (W) × 200 mm (H) - 1 pc.

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

400 kgf·m capacity - 1 pc. 20 kgf·m capacity - 1 pc.
(3 920 N·m/2 890 lb·ft) (195 N·m/145 lb·ft)
12 Hydraulic jacks
20-ton load - 2 pcs.
Protectors
13 Protectors and patches
Example of protector (see Fig. 6-1)
Used tire
14 Hand tachometer or digital tachometer

Pulse meter Adapter Engine speed sensor
15 Torque wrench
34 ~ 882 N·m capacity
(3 ~ 90 kgf·m/25 ~ 651 Ib·ft)
Number of protectors made: 10 pcs.
16 Safety life lines - 4 sets Fig. 6-1
17 Grinder
18 Halide torch or electric leak detector

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

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

8 mmø × 5 000 mm (L) - 2 pcs. For the tools which are not available locally,
(0.3 inø) (195 in L) place order to Hitachi in advance.
46
Note:
For the tools which are not available locally,
SPECIAL TOOLS Kit No. 915707 place order to Hitachi in advance.
Item Illustration Tool name Q'ty Usage
Tap to be screwed
1 4395305 1 in bolt hole for
Tap tighening the
side frame
Fig. 6-2
4093798
Torque wrench
100 ~ 410 N·m Used to tighten
2 1
10 ~ 42 kgf·m the bolts.
74 ~ 302 lbf·ft
capacity
Fig. 6-3
4093800
Used to tighten
Power wrench
3 1 the side frame
With wrench, socket
to track frame
P/No. 4298389
Max. output torque

4 410 N·m (450 kgf·m/3 253 lbf·ft) Fig. 6-4
4229414 Used to tighten

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

3 430 N·m (350 kgf·m/2 530 lbf·ft) Fig. 6-5
47
Note:
For tools which are not available locally,
place an order with Hitachi in advance.

Vacuum pump
Assembly ST6905
Used to create
Vacuum pump ST6440 1 set vacuum in the
Hose ST6326 hydraulic tank
Nipple PT 1/8 ST6066
Nipple PT 3/8 ST6068
Fig. 6-6
90˚ 2 45˚
(20)
Section A 15˚ 30˚

16
Bar 1 For use with

ø30
item no. 3
16
(820)
R8 50
R15 50 (50)
ø10
5
5
R36
Fig. 6-7
40
ø12
M20×2.5
For removing /
7 Pin removal/ inserting the various
1
insertion jig front-end attachment
pins
17 Fig. 6-8
Directions for use of the pin removal/insertion jig
Pin removal Pin insertion
Item no. 3 Item no. 2

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

Backhoe-Front (low-cab)
Fig. 1
ASSEMBLY CHART OF UPPERSTRUCTURE

Loader-Front (high-cab)
Fig. 2
51
Pattern 1
Parts required/procedure low-cab (Backhoe-front)
Item Part No. Part name Q'ty Weight: kg (lb) Remarks
00 ─── Upperstructure 1 35000.00 (77000.00)

02 5011450 Counterweight 1 17500.00 (38500.00)
03 4339819 Bolt 8 7.75 (17.05)
04 4264013 Washer 8 4.29 (9.44) ~S/No. 1096
04 4714669 Washer 8 1.28 (2.81) S/No. 1097~
05 4605479 Gasket 1 1.20 (2.64)
06 ─── Exhaust pipe 1 15.00 (33.00)
07 ─── Fender 1 213.00 (468.60)
08 ─── Fender (STD) 1 140.00 (308.00)
09 ─── Fender 1 160.00 (352.00)
10 ─── Fender 1 180.00 (396.00)
11 8081037 Handrail 1 17.40 (38.28)
13 ─── Mirror assembly 1 2.39 (5.26) Mirror assembly next to the fendery
14 ─── Mirror assembly 1 2.18 (4.79) Mirror assembly next to the cab
15 4401490 Chain 1 0.40 (0.88)
17 7053107 Step 1 18.60 (40.92)
19 ─── Duct assembly 1 88.60 (194.92) Duct assembly in front of radiator
20 ─── Duct assembly 1 82.90 (182.38) Duct assembly in front of oil cooler
22 ─── Side frame (R) 1 15200.00 (33440.00)
23 ─── Side frame (L) 1 15200.00 (33440.00)
24 J834214 Bolt 52 2.61 (5.74)
25 4244330 Spacer 52 2.24 (4.92)
27 7053250 Cover (R) 1 24.00 (52.80) ~S/No. 1103
27 7059399 Cover (R) 1 25.00 (55.00) S/No. 1104~
28 7053251 Cover (L) 1 24.00 (52.80) ~S/No. 1103
28 7059400 Cover (L) 1 25.00 (55.00) S/No. 1104~
30 7054334 Ladder 2 19.60 (43.12)
31 8068378 Step 2 13.20 (29.04)
32 8083483 Step 1 3.58 (7.87)
35 ─── Lamp, head 2 0.75 (1.65)
37 ─── Lamp assembly 1 1.00 (2.20) Ascent/decent-use lamp assembly
39 ─── Bolt assembly 6 0.15 (0.33) For the fender to the bettery box
40 ─── Bolt assembly 6 0.18 (0.39) For the fender to the cab
41 7046495 Handrail 1 21.80 (47.96)
42 8107887 Handrail 1 4.62 (10.16)
44 ─── Bolt assembly 8 0.18 (0.39) Duct mounting bolt assembly
45 J281225 Bolt, sems 8 0.05 (0.11) Duct assembly hinge mounting sems bolt
48 ─── Muffler cover 1 100.00 (220.00)
50 ─── Antenna 1 0.20 (0.44)
51 ─── Wiper assembly 2 0.60 (1.32)
A ─── Fender 1 204.00 (448.80) When the side ladder is being used
B ─── Ladder 1 252.00 (554.40)
C ─── Step 1 16.50 (36.30)
D ─── Camera 1 2.46 (5.41) ＊ Refer to page 54 and 84
E ─── Rear light 2 0.5 (1.1) ＊ Refer to page 54 and 84
F 4187329 O-ring 4 ── (──)
52
Pattern 2
Parts required/procedure high-cab (Loader-front)
Item Part No. Part name Q'ty Weight: kg (lb) Remarks
00 ─── Upperstructure 1 35000.00 (77000.00)

02 5011450 Counterweight 1 17500.00 (38500.00)
03 4339819 Bolt 8 7.75 (17.05)
04 4264013 Washer 8 4.29 (9.44) ~S/No. 1096
04 4714669 Washer 8 1.28 (2.81) S/No. 1097~
05 4605479 Gasket 1 1.20 (2.64)
06 ─── Exhaust pipe 1 15.00 (33.00)
08 ─── Fender (STD) 1 140.00 (308.00)
09 ─── Fender 1 160.00 (352.00)
10 ─── Fender 1 180.00 (396.00)
11 8081037 Handrail 1 17.40 (38.28)
13 ─── Mirror assembly 1 2.39 (5.26) Mirror assembly next to the fendery
14 ─── Mirror assembly 1 2.18 (4.79) Mirror assembly next to the cab
15 4401490 Chain 1 0.40 (0.88)
17 7053107 Step 1 18.60 (40.92)
19 ─── Duct assembly 1 88.60 (194.92) Duct assembly in front of radiator
20 ─── Duct assembly 1 82.90 (182.38) Duct assembly in front of oil cooler
22 ─── Side frame (R) 1 15200.00 (33440.00)
23 ─── Side frame (L) 1 15200.00 (33440.00)
24 J834214 Bolt 52 2.61 (5.74)
25 4244330 Spacer 52 2.24 (4.92)
27 7053250 Cover (R) 1 24.00 (52.80) ~S/No. 1103
27 7059399 Cover (R) 1 25.00 (55.00) S/No. 1104~
28 7053251 Cover (L) 1 24.00 (52.80) ~S/No. 1103
28 7059400 Cover (L) 1 25.00 (55.00) S/No. 1104~
30 7054334 Ladder 2 19.60 (43.12)
31 8068378 Step 2 13.20 (29.04)
32 8083483 Step 1 3.58 (7.87)
35 ─── Lamp, head 2 0.75 (1.65)
37 ─── Lamp assembly 1 1.00 (2.20) Ascent/decent-use lamp assembly
39 ─── Bolt assembly 6 0.15 (0.33) For the fender to the bettery box
40 ─── Bolt assembly 12 0.18 (0.39) For the fender to the cab
41 7046495 Handrail 1 21.80 (47.96)
42 8107887 Handrail 1 4.62 (10.16)
44 ─── Bolt assembly 8 0.18 (0.39) Duct mounting bolt assembly
45 J281225 Bolt, sems 8 0.05 (0.11) Duct assembly hinge mounting sems bolt
48 ─── Muffler cover 1 100.00 (220.00)
49 ─── Wiper assembly 2 0.60 (1.32)
50 ─── Antenna 1 0.20 (0.44)
53 ─── Step 1 126.00 (277.20)
54 ─── Fender 1 171.00 (376.20)
56 ─── Cab assembly 1 640.00 (1408.00)
57 ─── Seat assembly 1 44.20 (97.24)
58 ─── Duct assembly 1 2.25 (4.95)
59 ─── Duct assembly 1 3.10 (6.82)
60 ─── Box assembly 1 6.86 (15.09)
A ─── Fender 1 204.00 (448.80) When the side ladder is being used
B ─── Ladder 1 252.00 (554.40)
C ─── Step 1 16.50 (36.30)
D ─── Camera 1 2.46 (5.41) ＊ Refer to page 54 and 84
E ─── Rear light 2 0.5 (1.1) ＊ Refer to page 54 and 84
F 4187329 O-ring 4 ── (──)
53
Item Part No. Part name Q'ty Remarks
D ─── Camera 1 With rear camera With no rear camera

Bolt, sems~4 ───
Rear camera harness~1 Rear lamp harness~1
Clip~13 Clip~11
Bolt~13 Bolt~11
E ─── Rear light 2 Rear light~2

Bracket~2
Bracket~2
Bolt, sems~6 (For installing the rear light)
Clip, band~1 (For fixing the harness at rear light)
Clip~2 (For fixing the harness at rear light)
54
7-2 Connection of upperstructure and side frames
Step 1 Lift
Preparation of the side frame assembly (left)
1 Lift the side frame assembly (left) 23 as illustrated in

Fig. 1.
Wire ropes
26 mmø×
8 000 mm
Note:
Apply protectors at 12 points a , b and c , indicated
by to prevent the wire ropes from breaking.
Side frame (700G) 23 weight: 15 200 kg (33 440 lb)

Side frame (900G) 23 weight: 15 900 kg (34 980 lb) a
b 23
Wire rope: 2 pcs.
26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L) Front side Fig. 1
c
Protector: 12 pcs.
2 Put the side frame assembly on the ground to Set the

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

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

by e in Fig. 4) of the side frame.
3 Check the surfaces for damage or scratches.

Detail B
e
Note:
If they are damaged, repair and/or refinish them.
Fig. 4
55
Step 2
Wire rope handling work of the Upperstructure 00
Note: The instructions given below are applicable to

the side frame connection for the low cab-use
upperstructure. The same instructions will be
applied for the high cab-use uppper structue.
1 Prepare two 40 tonne (44 US ton) cranes for lifting

Fig. 5
the upperstructure assembly 00 . Detail C
Wire ropes at front side
2 Attach wire ropes to the upperstructure assembly
Detail D
illustrated in Figs. 6 and 7. Wire ropes at rear side
1 Wire ropes and chain block at the front side of the Wire rope Wire rope
26 mmø× 36 mmø×
upperstructure. 10 000 mm
2 000 mm
Apply the protectors and wooden block a to the
Chain
pins as shown in Figs. 6-a and 6-b. block
Wire rope
Fig. 6-a
2 Wire ropes at the rear side of Wooden block a 26 mmø×
8 000 mm
the upperstructure. Protector
Apply the protectors to the
beam of the main frame as
shown in Fig. 7.
Left side
Upperstructure assembly 00
Weight: 35 000 kg Wire rope
(Low-cab/High-cab) (77 000 lb) 26 mmø×
2 000 mm
Wire rope: 1 pc. 26 mmø × 8 000 mm (L)

(1.0 inø) (312 in L)
Wire ropes: 2 pcs. 26 mmø × 2 000 mm (L) Fig. 6-b Protectors

(1.0 inø) (78 in L)
Protectors
Wire rope: 1 pc. 36 mmø × 10 000 mm (L) Fig. 7
(1.4 inø) (390 in L) Lift
Lift
Protector: 10 pcs.
Chain block: 1 pc. for 10 tonne (11 US ton) load
Wooden block a :1 pc.
★
3 Lift the upperstructure assembly horizontally as
illustrated in Fig. 8.
Notes: Rope
i) Level the upperstructure by adjusting the preset
chain blocks. Hold
ii) It is safe to attach a rope on the sections
Rope
indicated by ★ in order to guide it.
★
Rope: 2 pcs. 10 mmø × 5 000 mm (L) Hold
(0.4 inø) (195 in L)
Fig. 8
CAUTION: CAUTION:
i) Be sure to use the protectors to prevent the wire When doing the joining work of the side frame, station
ropes from breaking. (Fig. 6 and 7) the sub-leaders each at the front and rear locations of
ii) Never allow anyone to stand directly beneath the the upperstructure to do the work following the signs of
lifted machine. the leader with utmost care so as not to break the
component parts.
56
Step 3
Lift
Preparation of the track frame
1 Positioning side frame

Lift
While lifting the upperstructure assembly with a crane,

turn the track frame at 90°. The side frame is
assembled at the bottom of the upperstructure.
Notes:
i) To position the side frame, the upperstructure
must be turned after starting the engine.
Before starting the engine, be sure to confirm the
coolant and oil levels according to the Operation
Manual or check them with the instruments. etc.
ii) When turning the track frame, be sure to let two
Track frame 90°
work crew stand at the front and rear sides of the
upperstructure and give instructions for gradually
Turning
turning the track frame.
iii) The rear side of the track frame incorporates the Fig. 9
back-and-forth travel pipings and hoses.
iv) Be sure to set the engine speed to low idle Hold
before stopping the engine.
For high-cab machines with the cab removed,
care should be particularly taken. Hold
Under side
(Right & left)
Under side
(Right & left) Fig. 10
2 Cleaning and finishing
1 Clean the front and rear & right and left surfaces
(indicated by in Figs.10 and 11) of the
track frame.
2 Check the surfaces for damage or scratches.
Detail E
Note:
If they are damaged repair and/or refinish them. Spot facing
3 Clean all spot facing surfaces of the track frame.
Under side Fig. 11
57
Step 4
Lift
Connecting the upperstructure to the side frame (left)
Lift
1 1 Move the upperstructure assembly horizontally in

the direction of the arrow .
Note:
Set the travel device side of the side frame
assembly and the Travel Piping and hoses side of
Side frame
the track frame assembly in the same direction. (left)
(See Fig. 12)
Travel Device
Fig. 12
2 Moving the upperstructure horizontally in the
direction of the arrow, align the centers of the Detail F
connecting parts of the side frame and track
frame.
Lift & move
Track Side frame

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

Fig. 13
Hold
Fig. 14
58
2 1 Align the bolt holes of the side frame and track Hold
frame to be connected and then connect them
together with bolts 24 and spacer 25 .
Notes:
i) Be sure to apply a suitable lubricant to the fixing
bolts 24 before tightening. Use the lubricant
made by mixing a white zinc jelly and spindle oil
in 1:1 proportion.
ii) Apply a lubricant to the under-side of the bolt
head marked with ＊, before insertion as
iii) Place the spacer 25 on the bolts 24 with the
chamfer directed to the bolt head.
iv) Tighten all bolts till the surfaces engage fully.
v) Confirm that there is no space between the
contacted surfaces.
Fig. 15
Detail G
25
Detail H
25 Section a
24
Chamfer 24
Fig. 17
25
Note:
Be sure to similarly treat all the remaining bolts.
2 Tighten the bolts 24 on the front side following the

same procedure as that for those on the rear side.
Fig. 16
Detail I
3 Tighten temporarily using a power wrench.
CAUTION:
Perform this Step avoiding your hand getting caught by
the reaction force bar of the power wrench.
Fig. 18
59
Step 5 Detail J
Hold
Connecting the side frame (right) to the track frame
1 1 Place 2 wooden blocks under the other side of the

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

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

connected to the track frame.
Wire ropes
3 Check the surfaces for damage or scratches. Side frame (right) 22 26 mmø×
8 000 mm
Note:
If they are damaged, repair and/or refinish them.
a
3 1 Lift the side frame (right) 22 as illustrated in Figs.
21 and 22.
b
Note:
Fig. 21
Apply protectors at 12 points a , b and c , indicated c
by to prevent the wire ropes from breaking.

Hold
Lift & move
Wire ropes used: 2 pcs. at
26 mmø × 8 000 mm (L)
(1.0 inø) (312 in L)
Protectors: 12 pcs.
2 Moving the side frame assembly (right)

horizontally in the direction of the arrow, align the
centers of the connecting parts of the side frame Track frame
and track frame.
Side frame
(right)
Fig. 22
60
4 As explained in "Step 4" apply a lubricant to the fixing
bolts before installing. Hold
Hold
1 Connect the track frame to side frame.
2 Align the bolt holes of the side frame and track

frame to be connected and then connect them
together with bolts 24 and spacer 25 .
Notes:
bolts 24 before tightening. Use the lubricant
made by mixing a white zinc jelly and spindle oil
in 1:1 proportion.
iii) Place spacers 25 on bolts 24 with the chamfer
directed to the bolt head. Fig. 23
iv) Tighten all bolts till the surfaces engage fully Detail K
v) Confirm that there is no space between the
contacted surfaces.
a 25
Detail L
25 Section a
Chamfer
24
Fig. 25
Fig. 24
Note:
Be sure to similarly treat all the remaining bolts. Detail M
3 Tighten the bolts 24 on the front side following the

same procedure as that for those on the rear side.
4 Tighten temporarily using a power wrench.
CAUTION:
Fig. 26
61
Step 6
Removing the wooden blocks Hold
Hold
Wooden blocks
1 1 Lower the crane. Fig. 27

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

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

side frame.
a
Fig. 28
Take off the crane

wire ropes
2 1 Remove the wooden blocks.

2 Retract 2 hydraulic jacks a (indicated by )
at the same time to ground the track frame.
3 Take off crane (Rear side) wire ropes lifting the
side frame.
Fig. 29
62
Step 7 Lift
The tightening procedures for the bolts used to attach the
track frame are described below.
CAUTION: Track link
Do not loosen valve a quickly or loosen it too much as

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

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

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

link and side frame
Fig. 34
63
Hold
Step 8
Retightening the remaining bolts
1 Retighten the right-side bolts.

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

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

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

(400 kgf·m/2 890 lbf·ft)
CAUTION:
3 Retighten the bolts located on the left side.
Fig. 37
Detail Q
Power wrench
(4093799)
Fig. 38
64
7-3 Connection of travel motor hoses
Step 1
Connection of the travel motor hoses
1 Remove the wires that are holding the travel motor

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

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

110 N·m
(11 kgf·m/81 lbf·ft) Fig. 1
Socket size: 00 mm Detail A
Notes:
i) Clean the surfaces of the travel motor to be
connected to the hoses.
ii) Make sure that there is no dust sticking to the
seat face of each hose.
iii) Be careful not to twist the hoses when
connecting them.
iv) Use O-rings F (P/No. 4187329~2) to install the
hoses. Apply a thin layer of sealant #98D to the
O-rings before installation.
Wires
3 Connect the travel motor pilot hoses e and f as Fig. 2

shown in Fig. 4.
Detail B
Tightening torque of hose e : 40 N·m
(4 kgf·m/30 lbf·ft)
Tightening torque of hose f : 95 N·m
Notes:
i) Clean the surfaces of the travel motor to be
connected to the hoses.
ii) Make sure that there is no dust sticking to the
seat face of each hose.
iii) Be careful not to twist the hoses when Fig. 3
connecting them.
Detail C
F
Clamps g
4 Hold the travel motor hoses c , d and pilot hoses e ,
f in place with clamps g , h .
Clamps h
Connect the hoses on the opposite side of the
travel motor in the same way. F
5 After the oil has run out, clean the parts carefully. c
d
f e Fig. 4
65
Step 2
Installation of covers, ladders and steps
1 Install the covers 27 , 28 . Detail D
Note:
Install the mounting bolts, etc. on the opposite side.
Cover 27 (R) weight: (~S/No. 1103) 24 kg (53 lb)

Cover 27 (R) weight: (S/No. 1104~) 25 kg (55 lb)
Cover 28 (R )weight: (~S/No. 1103) 24 kg (53 lb)
Cover 28 (R )weight: (S/No. 1104~) 25 kg (55 lb)
Tightening torque of M00 bolt: 210 N·m

27 (R)
「 28 (L)」
Fig. 5
Notes:
i) Apply lubricant to the mounting bolts, fit all bolts
in place, and then tighten them with the specified
torque. 30
ii) Similarly, make assembly on the opposite side.
2 Install the ladders 30 and steps 31 .

31
Note:
Ladder 30 (For 700 mm shoe) weight: 20 kg (44 lb)

Ladder 30 (For 900 mm shoe) weight: 25 kg (55 lb)
Tightening torque of M00 bolt: 210 N·m 30

31
Step 31 weight: 13 kg (29 lb) Fig. 6

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

are securely tightened.
Fig. 7
66
7-4 Assembly of cab & handrail, step and ladder etc.
OUTLINE
Pattern 1 Backhoe-Front (low-cab)
1 Installation mirror, head lamps, antenna, and wiper on the cab.

2 Installation of fenders, steps and ladder, etc.
3 Installation of fender, handrails and step.
4 Installation of duct assembly.
5 Instaration of air cleaner caps and exhaust pipe.
Pattern 2 Loader-Front (high-cab)
1 Remove the protective special sheet from the cab.

2 Preparation of the cab.
3 Installation of miscellaneous parts on the cab.
4 Installation of cab on the cab bed.
5 Install the seat.
6 Installation of fenders, step and ladder, etc.
7 Conecting air conditoner parts, electric parts and window washer hose.
8 Installation of fenders, handrails and step.
9 Installation of duct assembly.
10 Installation of air cleaner caps and exhaust pipe.
Pattern 1 Backhoe-Front (low-cab)······················································································P68, 73, 80~82
Fig. 1
Pattern 2 Loader-Front (high-cab)·····················································································P69~72, P74~82
Fig. 2
67
Step 1
Backhoe-Front Cab Assembly (Low-cab)
Backhoe-front machines are shipped according to the low-cab specification.
Installation of miscellaneous parts on the cab.
Note:
1 Mount the mirror 14 on the cab.
2 Install the head lamps 35 and lamp 37 on the cab and

connect the cords.
3 Install the antenna 50 on the cab and connect the

cords. Fig. 3
4 Mount the wipers 51 on the wiper motors and connect

the cords.
Detail A
35 Head lamp×2
Wiper assembly
51 37 Lamp×1 50
Antenna
Wiper assembly
51
14
Fig. 4
68
Step 2
Loader-Front Cab Assembly (High-cab)
Loader-front machines are shipped according to the

high-cab specification, but the cab is disassembled.
The following procedures are required.
Fig. 5
Detail B
1 Removing the special sheet
Remove the protective special sheet from the

cab.
Special sheet
Fig. 6
Detail C
2 Preparation of the cab 56 .
Place the cab on wooden blocks, as shown in

Fig. 7.
Cab 56 weight: 640 kg (1 408 lb)
Wooden blocks: 2 pcs.

56
Note:
The wooden blocks must be able to carry more
than 400 kg (880 lb) load.
Wooden block
Fig. 7
69
3 Installation of miscellaneous parts on the cab 56 .
Note:
1 Mount the mirror 14 on the cab.

2 Install the head lamps 35 , lamp 37 on the
cab and connect the cords.
3 Install the antenna 50 on the cab and
connect the cords.
4 Mount the wiper blades 49 on the wiper
motors and connect the cords.
5 Install the rope ladder box assembly 60 .
Box assembly 60 weight: 7 kg

(15 lb) Notes:
Tightening torque of M10 bolt: 50 N·m i) Apply lubricant to the bolts before
(5 kgf·m/37 lbf·ft) installing.
Width across flats: 17 mm ii) After screwing all the bolts by hand, tighten
them to the specified torque.
Detail D
35 Head lamp×2
Wiper assembly
49 37 Lamp×1 50
Antenna
56
Wiper assembly
49
14
60
Fig. 8
70
4 Installation of cab Detail E
Lift
1 Attach wire ropes to cab assembly 56 as shown in Wire ropes

10 mmø×
Fig. 9. 3 000 mm
Cab assembly 56 weight: 647 kg

(1 423 lb)
Wire rope: 4 pcs. 10 mmø × 3 000 mm (L) 56

(0.4 inø) (117 in L)
Shackle: 4 pcs.
for 0.5 metric tonne (0.55 US ton) load
CAUTION! Fig. 9
Never allow anybody to stand directly beneath the lifted
cab.
2 Keep the cab level during lifting, as illustrated in Lower

Fig. 9.
3 Sling cab 56 , lower it slowly, and then place it on
the cab bed.
4 Install the cab on the cab bed.
Note: 56
5 Tighten the cab connecting nuts a and washers

b. Cab bed
6 Tighten the cab connecting bolts c , spring
washers d and washers e .
Tightening torque of M16 nut a : 270 N·m Fig. 10

Width across flats: 24 mm Hold
Tightening torque of M10 bolt c : 50 N·m

Notes: Detail F
i) Apply lubricant to the nuts before
Bolt c
installation.
ii) Tighten all nuts to the specified d Cab
torque after first screwing in finger e
tight.
Fig. 12
Fig. 11
Detail G
a
b
Fig. 13
5 Remove the wire ropes attached to the cab.
Fig. 14
71
6 Install the operator seat assembly 57 as Detail H
illustrated in Fig. 15. Operator seat
assembly 57
Note:
Install the mounting bolts, etc. on the opposite
side.
Operator seet 57 weight: 44 kg

(99 lb)

Notes:
i) Apply a lubricant to the bolts before
installing.
ii) After screwing all the bolts by hand, tighten
them to the specified torque.
Fig. 15
72
Step 3-(a) (Low-cab Parts)
Installation of fenders, steps, ladder, etc.
1 Wire ropes required 2 1 Install fenders 07 , 09 , A (or 08 ), steps 17 , C and

side ladder B on the base machine. To install
Wire rope: 4 pcs. fender 07 by the side of the cab, use bolts 40 .
8 mmø × 5 000 mm (L) 2 Install chain 15 to the cab and fender 07 .
(0.3 inø) (195 in L)
Fender 07 weight: 213 kg (469 lb) Note:

Fender 08 (STD.) weight: 140 kg (308 lb) Install the mounting bolts, etc. on the opposite side.
Fender 09 weight: 160 kg (352 lb)
Fender A weight: 164 kg (361 lb)
Ladder B weight: 252 kg (554 lb) (5 kgf·m/37 lbf·ft)
Step C weight: 17 kg (37 lb) Width across flats: 17 mm
Chain 15 weight: 0.5 kg (1 lb)
Step 17 weight: 19 kg (42 lb)
Notes: Width across flats: 24 mm
i) Apply lubricant to the bolts before installing.
ii) After screwing all the bolts by hand,tighten them
to the specified torque.
Detail I
BEFORE
17
15
07
(Use 6 bolts 40 .)
A
B
08 (STD) 09 Fig. 16
Detail J
AFTER
C
15
17
07
B
A
OR 09
(STD) 08 Fig. 17
73
Step 3-(b) (High-cab Parts)
Installation of fenders, steps, ladder, etc.
1 Wire ropes required 2 1 Install fenders 54 , 09 , A , steps 17 , C , 53 and

side ladder B on the base machine. To install
Wire rope: 4 pcs. fender 54 by the side of the cab, use bolts 40 .
8 mmø × 5 000 mm (L) : 2 Install chain 15 to the cab and fender 54 .
(0.3 inø) (195 in L)
Fender 08 (STD.)weight: 140 kg (308 lb) Note:

Fender 09 weight: 160 kg (352 lb) Install the mounting bolts, etc. on the opposite side.
Fender 54 weight: 171 kg (376 lb) Tightening torque of M10 bolt: 50 N·m
Fender A weight: 164 kg (361 lb) (5 kgf·m/37 lbf·ft)
Ladder B weight: 252 kg (554 lb) Width across flats: 17 mm
Step C weight: 17 kg (37 lb)
Chain 15 weight: 0.5 kg (1 lb) Tightening torque of M16 bolt: 270 N·m
Step 17 weight: 19 kg (42 lb) (27 kgf·m/200 lbf·ft)
Notes:
Detail K
17
BEFORE
15
(Use 12 bolts 40 .)
54
53
STD. 08 09 Fig. 18
Detail L
AFTER
C
15
17
54
53
B
A
OR 09
(STD) 08
Fig. 19
74
3 Connection of air conditioner parts, electric parts and
window washer hose.
Note:
This procedure should be used after the high-cab
specification cab is installed.
1 Connection of the duct
Note:
1) Connect the air duct a to the air conditioner

unit. Fig. 20
(1 kgf·m/7.3 lbf·ft) Detail M
2) Connect the air duct b to the air duct a .
3) Connect the air filter c to the air duct b .
Note:
Pay attention to the installation direction of the air
filter.
4) Connect the air bracket d to the airduct b .

Notes:
a
b
c
Fig. 21
75
2 Installation of the electrically-mounted parts box Detail N
Note: b c
1) During shipment, the electrically mounted

parts box a is fixed onto the sheet with a clip
band and covers b and c are temporarily
attached to the cab.
1) Install the electrically mounted parts box a to
the cab ceiling as shown in Fig. 23.
2) Secure the electrically mounted parts box a
and covers b , c by tightening the bolts as
shown in Figs. 24 and 24-a. a
Tightening torque of M00 bolt d : 50 N·m

Note:
Apply Loctite #242. Fig. 22
Tightening torque of M00 bolt e : 50 N·m

Width across flats: 17 mm Detail O
a
Detail P
Fig. 24-a
a
e
Fig. 23
Notes:
Fig. 24
76
3 Installation of the duct assemblys 58 and 59
Note:
1) Assemble duct assemblies 58 , 59 as shown in

Fig. 27.
2) Connect the harness to the back of the cigar
lighter socket on the left side of rear tray 59 .
Refer to Fig. 26.
3) After assembling the bolt a , fit the cap b and
rubber c in place.
4) Assemble the bolt d .
Duct assembly 58 weight: 2.25 kg (4.95 lb)
Duct assembly 59 weight: 3.10 kg (6.82 lb)

(1 kgf·m/7.3 lbf·ft)
Width across flats: 13 mm Fig. 25
Notes:
Detail Q
58
b Mounting bolt
c
a
Mounting bolt
59
d Fig. 27
Fig. 26
77
4 Connect the wire harness f to wire harness g
and fix them onto the cab with the clip and bolt h .
Tightening torque of M10 bolt h : 50 N·m

h
f
h
Fig. 28
5 Install the covers b and c to the wire harness g .
Tightening torque of M10 bolt : 50 N·m

78
6 Connection the electric parts of radio. Front
1) Connection the electric wire coupler a .
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect couplers of identical marking.
Fig. 29
Detail R
Radio
Fig. 30
7 Connection the window washer.
1) Connection the window washer hose b .
Fig. 31
Detail S
Window washer
Fig. 32
79
Step 4
Installation of fenders, handrails and step
1 Wire ropes required 2 1 Install fender 10 , step 32 and handrails 11 , 41 , 42

on the base machine. To install fender 10 by the
Wire rope: 4 pcs. side of the battery box, use bolt 39 .
8 mmø × 5 000 mm (L) 2 Install mirror 13 on the handrail a .
(0.3 inø) (195 in L)
Note:
Fender 10 weight: 180 kg (396 lb) Install the mounting bolts, etc. on the opposite side.
Handrail 11 weight: 18 kg (40 lb) Tightening torque of M12 bolt: 90 N·m
Handrail 41 weight: 23 kg (51 lb) (9 kgf·m/66 lbf·ft)
Handrail 42 weight: 5 kg (11 lb) Width across flats: 19 mm
Notes: Note:
i) Apply lubricant to the bolts before installing. Stated here is the assembly procedure for the low-
ii) After screwing all the bolts by hand,tighten them cab-use upper structure. The same procedure will
to the specified torque. be applied for the high-cab-use upper structure.
Detail V
42 41 BEFORE
13
11
a
10
(Use bolt 39 .)
32
Fig. 35
Detail W
42 41 AFTER
13
11
10
32
Fig. 36
80
Step 5
Installation of duct assembly
1 Wire ropes required 2 Install the duct assembly 19 , 20 using bolts 44 bolt
sems 45 on the basic machine.
Wire rope: 4 pcs.

8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L) (Bolt 45 ) (9 kgf·m/66 lbf·ft)
Duct assembly 19 weight: 89 kg (196 lb)
Duct assembly 20 weight: 83 kg (183 lb) Tightening torque of M00 bolt: 140 N·m
(Bolt 44 ) (14 kgf·m/103 lbf·ft)
Note:
Stated here is the assembly procedure for the low-
Notes:
cab-use upper structure. The same procedure will
be applied for the high-cab-use upper structure.
Detail X
19 BEFORE
20
Duct assembly hinge
mounting sems bolt -4
45
Duct mounting bolt, 44

assembly -8
44
Duct assembly hinge 45

mounting sems bolt -4
Fig. 37
Detail Y
AFTER
19
20
Fig. 38
81
Step 6
Installation of exhaust pipe
※ Install exhaust pipe.
1 Remove the blind vinyl cover through the muffler

hole.
2 Install exhaust pipe 06 , using gasket 05 . (Fig. 40)
Note:
Exhaust pipe 06 weight: 15 kg Fig. 39

(33 lb)
Detail Z
Bolt
06
Note:
Install the exhaust pipe of the muffler on the
05
machine with the exhaust port backward.
3 Install muffler cover 48 . (Fig. 41)
Note:
Install the mounting bolts, etc. on the opposite side. Nut
Fig. 40
Muffler cover 48 weight: 100 kg
(220 lb)

(9 kgf·m/66 lbf·ft) 48
Notes:
Fig. 41
82
7-5 Installation of counterweight, camera and rear lamps
To install the counterweight, follow the installation Detail A

Hold
procedure for the low-cab-use upper structure stated
below. The same procedure will be applied for the high-
Wire ropes
cab-use upper structure. 26 mmø×
8 000 mm
Step 1 Wire ropes
26 mmø×
Shackle 8 000 mm
Installation of the counterweight
Detail B
1 1 Attach the wire rope with a shackle
to the eye plate provided on Wire rope
02
counterweight 02 as shown in Fig. 1.
Shackle Hold
2 Lift counterweight 02 as shown in Eye
Figs. 1, 2 and 3. plate Eye plate
Counterweight 02 weight: 17 500 kg Fig. 2 Fig. 1

(38 500 lb)
Wire rope: 2 pcs.

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

Fig. 4.
CAUTION:
counterweight.
Beam
2 Move the counterweight onto the rear beam as

shown. Fig. 4
Hold
3 Set the counterweight on the rear beam.
Fig. 5
83
4 1 Set the counterweight 02 with 8 bolts 03 and 8
washers 04 .
Notes:
bolts before tightening. Use the lubricant made Hold
by mixing a white zinc jelly and spindle oil in 1:1

proportion.
Bolt 03 weight: 7.8 kg (17.1 lb)

Washer 04 weight: (~S/No. 1096) 4.3 kg (9.5 lb)
Washer 04 weight: (S/No. 1097~) 1.3 kg (2.9 lb)

iii) Tighten all bolts till the surfaces engage fully.
iv) Confirm that there is no space between the
contacted surfaces.
Fig. 6
v) Assemble washer 04 in such way so that the
"darin hole" faces dowanward.
Detail C
Detail D
02 04
＊
03
Fig. 7
2 Tighten the counterweight with 8 bolts 03 .

02
Note:
Tighten with a power wrench as shown in Fig. 8.

(400 kgf·m/2 890 lbf·ft)
CAUTION:
04
Be sure to avoid your hand getting caught by the
03 Fig. 8
reaction force bar of the power wrench.
S/No. 1096 and older S/No. 1097 and above
Drain hole
5 Take off the crane wire ropes lifting the counterweight.
Fig. 8-a
84
Step 2
Installation of the camera ass'y and rear lamp ass'y
1 Install the camera D on the counterweight.
1 Install camera D .
Note:
Camera D weight: 3 kg (7 lb)

2 Connect electric wire coupler a .

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

Fig. 9
2 Connect electric wire coupler b and c .
Notes:
i) Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
ii) Connect the couplers on the labels.
Detail E
b
a
E Refer to page 52 and 53
c
D Refer to page 52 and 53
E Refer to page 52 and 53
Fig. 10
85
3 Check that all the tightening bolts of the superstructure
are securely tightened.
Detail F
Fig. 11
86
7-6 Greasing of swing bearing
Greasing (1) Detail A
1 The machine is provided with a electrically operated

grease lubricator connected to the hose reel and a
grease gun.
Operation procedure:
(1) Pull out the grease hose from hose reel b while
holding grease gun a .
(2) Stop pulling out when the reel clicks and desired
hose length is obtained; the hose will be locked
automatically.
(3) Connect grease gun a to the desired grease
fitting and pull the gun lever; grease will be a
supplied automatically by air pressure.
IMPORTANT:
Run the engine at medium speed or more when
supplying grease using the lubricator.
b Fig. 1
2 Start the engine.
3 Supply grease to 4 points as shown in Fig. 3.
Notes:
i) When using a lubricator, increase the engine
speed above medium speed.
ii) If an optional automatic greasing system is not
equipped, the EX1200-6 comes equipped with a
standard air grease gun. Grease up at the front Fig. 2
pins with the air grease gun manually.

Detail B
iii) Insufficient greasing will cause wear to the pins.
Swing bearing
Fig. 3
87
4 Lubrication mouthed
(1) Turn power switch d ON to activate the pump.

Grease is sucked up and supplied to high-pressure d
grease gun b .
e
IMPORTANT:
When the pump begins to suck grease, any air inside
pump a will be mixed in, making grease turn whitish.
Open check valve cock e to bleed this air-mixed
grease. Securely close check valve cock e when all a
air-mixed grease is bled out.
(2) Grab high-pressure grease gun b and pay out the Fig. 4
hose from hose reel c to the length required.
(3) Press hydro-chuck g protruding from high-

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

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

switch d OFF, then pull grease gun b lever to
release remaining pressure from grease gun b ,
pump a , and the hose so as to ensure long life of c
the components. A little grease will be discharged Fig. 5
at this time.
g
Note:
The hose has a limited service life. Periodically
inspect the hose for cracks, grease leakage, or any
other damage. If any damage is found, replace the
hose.
h
Fig. 6
88
7-7 Vacuuming (air purge work) & charging of refrigerant
Insufficient refrigerant quantity will reduce cooling capacity of

the air conditioner. Watch the sight glass on the receiver tank
during charging.
CAUTION:
DO NOT allow liquid refrigerant to contact eye or skin.
Liquid refrigerant will freeze eye or skin on contact Be
careful not to loosen connections in the air conditioning
circuit.
Detail A
IMPORTANT:
When filling the air conditioner with refrigerant, set the Sight Glass
key switch, located on the right control box in the cab, Clear
to the ACC position; turn on the main air conditioner No
Refrigerant
A/C switch on the left control box; turn on the auxiliary
cooler fan switch; and perform vacuuming of the circuit
through both the SUC and DEC ports of the Sufficient Quantity
compressor.
＊ Engine is ON as described in operation manual. Insufficient
Quantity
But do not get the engine started up.
Fig. 1
89
＊ Necessity of Vacuuming (Air Purge)
The following damage will be generated if the air or

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

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

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

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

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

will clog up refrigerant flow
and reduce cooling ability. Reduce cooling ability
Fig. 4
90
SUBJECT
MAINTENANCE OF MACHINES EQUIPPED WITH AN AIR CONDITIONER

CHARGED WITH 134a REFRIGERANT
OUTLINE
In order to prevent an atmospheric ozone layer from being harmed, we have completely shifted our production
from air conditioners using R12 refrigerant gas to those using R134a refrigerant gas. This procedures describes
how to handle the new refrigerant, R134a. A new compressor oil is also specified for each model, and care
should be directed to the compressor oil.
■ Compressor oil
The new R134a refrigerant gas is incompatible with the R12 conventional refrigerant gas. Compressor oil
dedicated to each model is specified on the next page.
■ Shipping
As production has been shifted to the new air conditioners, EX1200-6 machines will be shipped with
refrigerant gas charged at the factory. Thus, charging of refrigerant gas for delivery is no longer required.
Refer. to the following page for servicing precautions, etc.
PRECAUTIONS
The new R134a refrigerant gas is incompatible with conventional R12 refrigerant gas.
A new compressor oil is specified for each model.
Model Serial No. Type of refrigerant gas / amount Type of compressor oil / amount
Refrigerant gas: R134a Compressor oil: ND-OIL 8

EX1200-6 S/No. 1001 ~
Amount: 1,150 g Amount: 220 cc
Charging incorrect refrigerant gas or compressor oil will cause the air conditioner to be damaged very quickly.
91
SERVICE TOOLS
To perform maintenance of the air conditioner using R134a refrigerant gas on EX1200-5 machine, the following tools,
refrigerant, and compressor oil are required.
(These service tools are exclusively used for air conditioners with R134a refrigerant gas and are not compatible with
those for R12 refrigerant gas.)
■ Tools (R134a refrigerant gas charging tool kit)

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

Fig. 2
■ Adaptor (for connecting the evacuation pump)

Fig. 3
■ Tester (refrigerant leak detector)

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

■ Oil (ND-OIL8, R134a compressor oil - 250 cc)
■ Oil (ND-OIL8, R134a compressor oil - 1 set)
92
1 CHARGING REFRIGERANT GAS (R134a) AND PREPARATION
For EX1200-6 machine, both refrigerant gas and the oil compressor are charged in the air conditioners before shipment.
Thus, recharging them is not required during delivery.
The explanations given below deal with spontaneous refrigerant gas leaks caused by long-term storage at the place of
shipment, and how to perform service after operation. (The new gas is charged in the same way as conventional R12
refrigerant gases. However, the service tools, charging pressures, etc., differ for each gas.)
1.1 When refrigerant gas has been completely released

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

Check for compressor oil leakage (from the hose cap, damaged hose, etc.) and supply oil as required. (Make sure to
use the specified oil.)
Oil should be added into the compressor from the suction port by disconnecting the refrigerant hose from the
compressor suction side (on which "S" is stamped).
2 If a damaged hose has to be replaced, spray compressor oil on the O-ring at the hose cap to prevent it from being
damaged.
3 Replace the receiver tank (P/No. 4333461 ) because the desiccating agent inside will have degraded.
4 Perform evacuation.
Note:
The compressor shown in the connection diagram for the charging hose and service valves is different from the used
one on the actual machine connection. See next page for photos of the actual connection.
Evacuation
Why evacuation is required

The greatest attention should be paid to the presence of water in the unit when handling the air conditioner. Since
R134a refrigerant for air conditioners is insoluble in water, even a little water remaining in the unit may freeze in the
expansion valve during operation or cause the compressor valve to rust. Thus, it is required that any residual water in
the unit be removed as much as possible before charging refrigerant. The only way to minimize the water in the unit is
to boil it by evacuation and remove it in gas phase. A vacuum pump can be used to drain the water in the unit in a
relatively short time, by maintaining a vacuum.
Evacuation instructions
Check for gas temperature.
Charge refrigerant.
Check for air tightness.
Check for gas leaks.
Performance test.
Start evacuation.
Stop evacuation.
Charge gas.
Approx. 10 min. Allow to stand Correct gauge

More than for 5 min. readings
755 mm
Abnormal
gauge readings Charge refrigerant in gas phase
Tighten piping. at a gauge pressure of 1 kg/cm2
93
Service valve location (machines equipped with air conditioner using R134a refrigerant gas)
EX1200-6 Service valve location

High-pressure side service valve ............ on the upper part (cap on which "H" is embossed)
of the receiver tank
Low-pressure side service valve .............. near the compressor (cap on which "L" is embossed)
High-pressure H
side service valve
Low-pressure L
side service valve
Fig. 5
94
EVACUATION PROCEDURE
1 Gauge manifold connection

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

of the gauge manifold to the vacuum pump.
2 Evacuation
1 Open the high pressure valve (HI) and low
pressure valve (LO) on the gauge manifold.
2 Turn the vacuum pump switch on and perform
evacuation for about 10 minutes.
3 When the negative pressure scale on the low-
pressure gauge registers 755 mmHg or greater
(= speed at which a vacuum can be obtained),
turn the switch off and close the high pressure
valve and low pressure valve on the gauge
manifold.
Fig. 7
Evacuation
95
3 Airtightness check
1 Close the high and low pressure valves on the
gauge manifold and let stand for more than 5
minutes, then verify that the gauge pointer does
not indicate zero.
2 If the gauge pointer moves toward zero, air is
probably leaking from some location. Tighten the
pipe connections and evacuate again to check for
leaks.
4 Checking for gas leaks

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

charge refrigerant until the low-pressure gauge
reads 1 kg/cm2. After completing the charge, close
the high pressure valve.
4 Use the leak detector to carefully check for gas
leaks in the cycle.
5 Correct any leaking areas by tightening
connections.
Note:
Gas leaks should be checked only after verifying
that there are no fuel leaks or inflammables present,
to prevent any explosion or fire.
If refrigerant touches an open fire, poisonous gas
(phosgene) will be produced.
Fig. 9
Charging refrigerant used to check for gas leaks
96
5 Charging refrigerant gas.
Charge refrigerant gas from the high pressure side service valve first (Note: Make sure to stop the engine during
this work), then charge from the low pressure side service valve (Note: Do this while rotating the engine and
operating the air conditioner).
The high pressure side service valves are located on the compressor on the receiver tank
for EX1200-6 machine. You can find the valve by removing the cap embossed with an H.
The low pressure service valves for EX1200-6 machine are located on the compressor.
You can find the valve by removing the cap embossed with an L.
Note:
The connection diagram compressor shown for the charging hose and service valve is different from the actual
one used. Refer to the instructions given on page 94.
CHARGING REFRIGERANT
After completing the gas leak check, charge refrigerant gas for the freezing cycle according to the following procedure:
1 Charging from the high pressure side

1 Stop the engine, open the gauge manifold high
pressure valve and service can valve, then charge
refrigerant using approximately 2 service cans
(about 600 g).
EX1200-6 ........ approx. 1 000 ~ 1 200 g
CAUTION:
1) Never operate the compressor when charging.
Operating the compressor during this work is
very dangerous, since it causes the refrigerant to
flow in reverse, bursting the service can or hose.
2) Never operate the compressor without charging
refrigerant. This can cause seizing.
3) Do not open the gauge manifold low pressure
valve (this can result in liquid compression).
2 Close the gauge manifold high pressure valve and

service can valve.
Fig. 10
Charging refrigerant (engine stopped)
97
2 Charging from the low pressure side
(additional charging)
1 Verify that the gauge manifold high pressure valve
is closed.
2 Start the engine and open all vehicle doors.
Turn the air conditioner switch on.
3 Set the temperature control lever to "Coldest" and
the blower switch to "HI".
4 Set the engine to run at low idle.
5 Open the gauge manifold low pressure valve and
service can valve, then charge refrigerant until air
bubbles disappear from the receiver sight glass.
6 After charging the refrigerant, close the gauge
manifold low pressure valve and service can
valve, then stop the engine.
7 Carefully check for gas leaks with the gas leak
Fig. 11
detector.
Charging refrigerant (engine driven)
<REFERENCE> Gauge manifold readings

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

When the ambient temperature is too low to successfully complete charging, put the service can in water
warmed up to 40°C until the refrigerant pressure in the service can increases.
Notes:
Never heat the service can with boiling water or a direct flame.
This can cause it to burst. Always use warm water at 40°C or less.
98
SERVICE-CAN REPLACEMENT
When the service can becomes empty during charging,

replace it with a new one according to the following
procedure:
1 Close the high pressure valve and low pressure
valve on the gauge manifold.
2 Raise the service can valve needle and disc.
3 Install the service can valve on the new service
can.
4 Purge the air from the charging hose as follows:
1) Tighten the service-can valve once, then
loosen it slightly.
2) Slightly open the gauge manifold low pressure
valve.
3) When the refrigerant comes out from the
clearance between the service can and
service-can valve with a hiss, immediately
close the service can valve and gauge manifold Fig. 12
low pressure valve.
Air in the charging hose
Removing the gauge manifold

After complete charging, disconnect the charging hose
from the compressor as follows:
1 Press the L-shaped metal connector on the low
pressure side charging hose (blue) to the
compressor service valve so that the refrigerant
does not leak, then immediately disconnect the
charging hose from the service valve.
2 Immediately after the flare nut is removed,
disconnect the charging hose from the service
valve.
3 Let the hose stand until the high pressure gauge
shows as low a value as possible (10 kg/cm2 or
less).
4 Disconnect the high pressure side charging hose
(red) using the same method as for the low
pressure side.
5 Screw the service can valve handle into the can to Fig. 13
open a hole and continue charging.
Removing the charging hoses
Notes:
1) This work should be done as swiftly as possible to minimize refrigerant leaks. In particular, prompt
replacement is required for the high pressure side after the gauge reads a sufficiently low value, since the
compressor oil as well as refrigerant can rush out (always use a waste cloth).
2) Special care should be taken so that no refrigerant touches the skin or enters the eyes (use safety goggles).
99
Quantity of refrigerant to be charged
When refrigerant is completely released

EX1200-6 ........... 1 150 g (Use five refrigerant gas cans, P/No. 4351827 (300 g)×3 pcs.
and P/No. 4454005 (250 g)×1 pc.
Watch the sight glass (liquid eye) at the upper part of the receiver tank during charging.
Using the sight glass (liquid eye)
Note:
Sight glass (liquid eye) Fig. 14
100
1.2 If the quantity of refrigerant gas is insufficient
If the air conditioner does not work properly because of the quantity of refrigerant gas is insufficient, add refrigerant gas
according to the following procedure:
1 Use the tester (leak detector) to check for refrigerant gas leaks.
If any leakage is found at a cap, tighten it. If parts at the leaking location have to be replaced, perform maintenance
according to procedure 1-1.
When a large quantity of refrigerant gas leaks but the tester (leak detector) identifies the leaking portion
with difficulties, find out it while adding refrigerant gas (don't add refrigerant gas more than instructed ! For
quantity to be charged, see page 91.)
2 Charge refrigerant gas from the low pressure side charging port (while starting the engine and operating the air
conditioner). (See the instructions on pages 95 and 100)
Quantity of refrigerant to be charged
When the quantity of refrigerant is low.

Watch the sight glass (liquid eye) at the upper part of the receiver tank during charging.
Using the sight glass (liquid eye)
Note:
Sight glass (liquid eye) Fig. 15
101
1.3 Troubleshooting
The following are trouble shooting methods when using the R134a refrigerant gas charging tool kit, P/No. 4360564.
<Troubleshooting using the gauge manifold>
1 Normal
<CONDITION>
※ After warming up the engine, examine the
system under the following conditions:
Door: Fully open
Inside air or outside air: inside air
Engine rpm: Low idle
A/C suction port temperature: 30 ~ 35°C
Blower speed: HI
Temperature control: Coldest
<Normal gauge pressure reading>

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

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

continuously pass almost zero, check and
through the sight glass. repair leak area, then
evacuate.
③ The air blown out is
not cold.
Fig. 17
102
3 Refrigerant dose not circulate (clogged cycle)
and correct
① If the cycle becomes Clogged A/C ▼ Check the receiver,
completely clogged, cycle expansion valve, etc.
the low pressure side
gauge immediately ▽ A temperature
reads a negative difference is made
pressure. between the defective
IN and OUT ports.
② If the cycle tends to
get clogged, the low ▼ Make sure to evacuate
pressure side gauge after completing the
gradually begins to work.
show a negative
pressure.
Fig. 18
4 Water contamination in the cycle

and correct
① The A/C performs Expansion ▼ Check the expansion
properly at first, but valve is valve, etc.
after a while, the low frozen due to
pressure side gauge water con- ▼ Replace the receiver
reads a negative tamination. (or dryer).
pressure.
▼ Make sure to evacuate
after completing the
work.
Fig. 19
5 Poor compression in the compressor

and correct
① The low pressure side Damaged ▼ Check the compressor.
gauge reads a high compressor
value, while the high ▽ Poor compression of
pressure side gauge the compressor
reads a low value. <The compressor
body is not hot to
② Both sides read the the touch.>
same value
immediately after
turning off the A/C.
Fig. 20
103
6 Too much refrigerant/poor air cooling in condenser
and correct
① Both the low pressure Too much ▼ Check for amount of
and high pressure side refrigerant refrigerant.
gauges read high
values. Poor air ▼ Correct the refrigerant
cooling in the amount.
② No air bubbles can be condenser
seen in the sight glass ▼ Check and repair the
when decreasing the condenser fin.
engine speed.
▼ Check the vehicle
③ Poor air cooling. cooling system (electric
fan, fluid coupling,
radiator), etc.
Fig. 21
7 Air contamination in the A/C cycle

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

through the sight glass.
Fig. 22
8 Excessively opened expansion valve

and correct
① Both the low pressure Defective ▼ Check the expansion
side and high pressure expansion valve.
side gauges read high valve
values. ▼ Check the temperature
sensing sleeve
② The low pressure side arrangement.
piping is covered with
frost (condensation). ▽ This phenomenon
often occurs after
replacing the
expansion valve.
Fig. 23
104
< REFERENCE > Troubleshooting list: Poor air cooling
Air contamination
High-pressure side
pressure is too high Excessively charged refrigerant
Condenser covered with dust
Insufficient refrigerant
Damaged compressor
Normal High-pressure side discharge valve
pressure pressure is too low
Broken gasket (compressor)
Abnormal low pressure pipe
Normal air Normal (crushed, clogged)
volume pressure
Expansion valve open too much
Abnormal Low-pressure side Bad contact of temperature
pressure pressure is to high sensing sleeve
Excessively charged refrigerant
Insufficient refrigerant
Bad contact of temperature
sensing sleeve
Low-pressure side Frosted evaporator
pressure is to low
Abnormal low-pressure piping
Clogged expansion valve
Both high-pressure and

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

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

Abnormal blower
and motor Loose blower
Blower-related Blower in contact with heater case
Deformed blower
105
1.4 Inspection After Charging Refrigerant
Perform the gas leak test of the refrigerant and the test
run after charging the specified refrigerant volume. Gas Leak Test
1 Gas Leak Test of Refrigerant

This test is performed with the halide torch type
leak detector, but if the electric type leak detector
is used, very small amount of leaks can be
detected. Perform the gas leak test according to
the following procedure:
(1) Conduct the test by selecting a well ventilated
Fig. 24
place wherever practicable, and thoroughly
clean the oil spills at the joints of the charge
hose which occurred at time of charging the
refrigerant.
(2) Especially check the joints of the tubing
carefully.
(3) If gas leaks are found, tighten the joints and
test again.
(4) Be careful not to put your face near the flame If gas leaks, tighten joints.
of the combustion gas of the refrigerant for
long periods because it is poisonous gas.
＊ For the gas leak tester, use a special one for the
refrigerant.
Fig. 25
2 Test Run
Inspect each unit before test run.
(1) Operate the switch and inspect.
(2) Inspect the ON and OFF of the magnetic
clutch of the compressor.
(3) Inspect the compressor belt and the fan belt.
(4) Inspect the radiator cooling water.
(5) In addition, check to see if there is any articles
near the rotating unit and the exhaust
manifold.
After the inspection of each unit is completed to
confirm that there is no abnormality, operate the
cooler and inspect the performance.
The performance is measured by mounting the
Fig. 26
temperature gauge at the inlet port and the
discharge port of the cooler unit and measuring
the air temperature at the inlet and discharge
ports, and by mounting the manifold gauges at the
inlet/ outlet ports, and measuring the inlet and
outlet pressures.
The results are compared with the inspection
data, to judge whether good or bad.
106
(a) Test Conditions
Operate the cooler under the following test
conditions, and measure the pressure and
temperature after 5 ~ 10 minutes after the
discharge temperature has stabilized.
(1) Engine speed is set at 1 500 rpm.
(2) Air volume of the cooler is set at HI.
(3) Air is not blown from the front surface of
the condenser.
(4) Doors are closed and all the windows are
opened.
(5) Test is performed in the shade.
(6) Thermostat dial is set at "COOL" position.
(7) Temperature gauges are placed when
subjected directly to the inlet air and
discharge air.
(8) Two people will stay in the cab and
measure.
(b) Check Against Performance Table

Fig. 27
Test results are compared with the inspection
data. Dash Type Car Cooler Inspection Data
For example, Fig. 27 shows the inlet air

temperature at 24 ~ 28°C and the discharge
temperature at 8 ~ 13°C when tested at the
ambient temperature is 30°C with the dash
type.
Also the discharge pressure of the compressor
becomes 14 ~ 1 6 kg/cm2 G, and the suction
pressure becomes 1.5 ~ 2.5 kg/cm2 G.
Thus, compare the test results by taking
ambient temperature on the horizontal axis,
and by reading the temperature and pressure
on the vertical axis. If the test results are in
between the read values, then the cooler is
running normal. If the measured values
deviate from the values in between, the case
may be that there is an error in the test or
some trouble in the cooler. In that case, retest
or check again according to the trouble-
shooting procedures.
3 Final Inspection
After completing the test run and before delivering
to the customer, recheck the condition while
referring to the instruction manual.
Fig. 28
107

Machine model Serial No. Cooler No.
Installation date Installed by Measuring date
Cooler Installation and Check
Installation procedure:
1. Installing hoses.
2. Air purging.
3. Gas filling and leakage check.
4. Performance test.
Check items Checked by Remarks

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

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

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

High/low pressure
Engine operation at full speed for 60 minutes
108
7-8 Final check of superstructure Detail A
Step 1
Checking the levels.

a
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
Fig. 1
1 Check the coolant levels a in the radiator (See Fig. 1).
If the level is low, refill through the filler ports on the Detail B
radiator.
Refer to the OPERATION MANUAL for details.
b
IMPORTANT:
Do not remove the radiator cap while the coolant is still
hot, as high temperature coolant may gush out of the
radiator causing injury.
Gradually loosen cap b once the coolant temperature
has dropped.
Fig. 2
Check that the coolant level is between the HIGH and
LOW marks on the level gauge. Remove the radiator Detail C
cap and add coolant if the level is low.
c
2 Check the oil levels c in all reduction gears for swing

reduction devices.
CAUTION:
The machine will be hot immediately after operation.
Allow the machine to cool adequately before checking
the oil levels. Fig. 3
Detail D
3 Check the oil level d in the engine oil pan.
CAUTION: d
The machine will be hot immediately after operation.
the oil levels.
4 Check the oil levels e in the final drives. (both sides)

Refer to the OPERATION MANUAL for details. Fig. 4
Detail E
IMPORTANT:
Never stand in front of the final drives when doing this
work.
Loosen the plug by 2 to 3 turns to allow any residual
pressure in the travel device to escape, before fully
removing the plug. e
If the plug is removed without letting residual pressure
escape, the plug and gear oil may gush from the
machine, causing injury. Do not stand or place your
face directly in front of the plug. Fig. 5
109
5 Check the fuel level in the fuel tank. Detail F
CAUTION:
Handle fuel carefully. Shut the engine off before
fueling. Do not smoke while you fill the fuel tank or
work on the fuel system.
Check fuel level gauge a on the monitor panel. Add

fuel via fill cap b if necessary. The fuel capacity is
approximately 1 470 liters (388 US gal). Fig. 6
Detail H Detail G
b
a
Fuel level
gauge
Fig. 8 Fig. 7
Fig. 9
Detail I
6 Check the pump transmission oil level.
1 Remove dipstick c . Oil must be between the

marks.
2 If necessary, add oil after returning the dipstick to
its original position.
CAUTION:
The machine will be hot immediately after operation. c
the oil levels.
Fig. 10
110
Detail J
Note:
The person in charge of assembly must confirm the
check items in this step. Incorrect operation will
damage the equipment.
7 Checking the hydraulic oil level.

Check that the level of oil in the hydraulic tank is above
the range indicated in the oil level gauge.
Fig. 11
Detail K
Note:
Release the air from the main pump at the same
time as you add hydraulic oil. (See page 100 for
details of the air release procedure.)
Fig. 12
Step 2
1 Connecting the battery cables to the batteries.

Before connecting the battery cables, clean of the
anticorrosive and rust from the connections.
2 Checking the liquid level of battery.
Check the liquid level of battery.
Fig. 13
Detail L
Connecting the battery cable Fig. 14
111
112
7-9 Releasing the air from the main pumps
Detail A
IMPORTANT:
If the hydraulic pump is not filled with oil, it will be Plug
damaged when the engine is started.
The machine is equipped with three main pumps.

Bleed air from these pumps after add hydraulic oil.
1 Remove air bleed plugs a , b , c (three for upper

pumps and lower pump) on side of each pumps.
2 Fill the pump with oil through air bleed plugs a ,
b , c port on side of each pumps until oil flows Fig. 1
out of air bleed plug a , b , c hole.
3 Temporarily tighten air bleed plugs a , b , c on
Detail B
each pumps, start the engine and run at slow idle.
Loosen one of air bleed plugs a , b , c slightly
until oil flows from plug port to release trapped air Front pump
completely. Tighten air bleed plug. Repeat this
step for the rest of plugs. a
4 Purge air from the hydraulic system by running the
engines at slow idle and operating the control b
levers slowly and smoothly for 15 minutes.
5 Position the machine as illustrated in the oil level
checking procedure.
6 Turn the auto-idle switch off. c
7 Stop the engines. Remove the key from the key
switches.
8 Pull the pilot control shut-off lever to the LOCK
position. Rear
pump
9 Check the hydraulic oil tank gauge. Add oil if
necessary. Lower pump
Fig. 2
1 Retighten air bleed plugs securely.
Tightening torque: 157 to 176 N·m

16 to 18 kgf·m
116 to 130 lbf·ft
CAUTION!
This operation must be done slowly. Avoid abrupt
operation!
2 Confirm hydraulic oil level in the hydraulic tank. Add

hydraulic oil if required.
Fig. 3
3 After the oil has flowed out clean the parts carefully.
113
114
7-10 Trial operation of superstructure
Trial operation
1 1 Start the engine.

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

the hydraulic excavator before starting the operation.
Traveling Fig. 2
2 Confirm that machine noise is maintained at specified

levels.
Fig. 4
Fig. 3
115
7-11 Disassembly procedures for shipment
1. Procedure (Backhoe front) ·············································································· 117
2. Procedure (Loader front) ·············································································· 119
116
Detail A
1. Procedure (Backhoe front)

Wrap edges of the hose in vinyl bag
Plug - 2 and hold in place with wire, etc. Mirror assembly Mirror assembly Duct assembly in front of radiator Duct assembly in front of oil cooler
next to the fendery next to the cab
Plug - 4
(To be installed to bottom as well)

(With rear camera) (With no rear camera)
Rear camera
Muffler cover Pipe, exhaust
(To be packaged separately in air bag cushioning material)

For installing the rear camera~4
Rear camera harness Rear light harness
Step in front of cab (Washer, plain 4338575)

(Bolt J901402) (Bolt, sems J281225)
Install the mounting bolts, Install the mounting bolts,
Install the mounting etc. on the opposite side. etc. on the opposite side. Duct mounting Duct assembly hinge mounting
bolts, etc. on bolt, assembly - 8 sems bolt - 8
the opposite side. Protect the antenna (Clip 4190261) (Clip 4190261)
Gasket with vinyl bag, etc. For fixing the harness~13 For fixing the harness~11
Sheet~1
(rust prevention)
Turn over the suspending Wrap this part in vinyl bag Turn over the suspending (Bolt, sems J271025) (Bolt, sems J271025)
Handrail above the fuel tank and secure with tape. Cover it Cover the front of the radiator and oil hook to install.
hook to install. For fixing the harness~13 For fixing the harness~11
with sheet and fix with the rope cooler with plywood.
that is attached to the sheet. Scrap the removed gasket (Plywood mounting bolt
Then, fix in place with wire. and send out a new gasket. J281235 - 12)
Antenna ※Refer to Note 9.
Counterweight Wiper assembly~2
Install the mounting Install the mounting

Counterweight tightening
bolts, etc. on the bolts, etc. on the
washer - 8
opposite side. opposite side.
Ascent/decent-use
lamp assembly Lamp, head - 2
Install the mounting
bolts, etc. on the Install the mounting bolts,
opposite side. etc. on the opposite side.
Handrail above the oil cooler
Apply anti-rust lubricant.
Attach the pins. Bracket~4
Cover (R)
(7059399)
Counterweight tightening bolt - 8 Cover (L) Washer~8
(7059400)
Bolt~8
Side frame
Chain Upper structure, tightening bolt - 52 Install the mounting Plug - 2
main body bolts, etc. on the Nut~8
Side frame opposite side.
Plug - 2
tightening 700mm shoe-use 900mm shoe-use
Frame, side (L) spacer - 52 Ladder - 2 Ladder - 2
Step next to the battery cover Step next to the side frame - 2 Slide ladder Frame, side (R) Rear light~2 Bracket~2 Nut - 4
Slide ladder-use
Step Install the mounting
Cap - 4
bolts, etc. on
the opposite side.
Install the mounting O-ring - 4/8
bolts, etc. on the Install the mounting
opposite side. bolts, etc. on the Bracket~2
opposite side.

Fender next to the hydraulic (Washer 4114405) (Washer 4114405)
oil tank - for standard (Washer, spring A590916) (Washer, spring A590916) For installing the rear light~6
(Bolt J921655) (Bolt J921680)
bolts, etc. on the
Assembly bolt for Assembly bolt for opposite side.
installing the fender installing the fender (Clip, band 4055312)
STD track Full truck
Install the mounting next to the battery box - 6 next to the cab - 6 guard guard
bolts, etc. on the 700G shoe For fixing the harness at rear light~1
opposite side. 900G shoe 1. This drawing shows how to disassemble EX1200-6 inside the factory for shipment.
Install the handrail coupling plate 2. Disconnect the minus side of battery body earth before disassembly.
(Clip, band 4259220)
to the fender. Install bolts to the plate. 3. For covers, plugs and other such necessary parts for packaging, use those contained
Install the mounting Fix the pilot hose For fixing the harness at rear light~2 in the "base machine shipment parts" kit no. 9106314 (item numbers in □ ).
Install J901630 bolts, etc. on the Fender next Fender next Install J901630 in place with clip band 4. Cover the electric wire connectors with vinyl bag and fix in place with clip band or tape.
on the opposite side. Fender next to the cab opposite side. to the engine to the battery box on the opposite side. Handrail next to the battery box
Plug - 2 5. Rust-proof around all bolts, frame coupling parts, screw holes, machined surface, etc.
Fender next to the hydraulic oil tank 6. Grease up the track link and make it taut.
- when the slide ladder is being used Install the mounting 7. For engine anti-freeze agent, use TES900-200.
bolts, etc. on the Plug - 2 8. After disassembly, replenish the base machine with hydraulic oil.
opposite side. Hydraulic oil level: up to the 100mm level from the hydraulic oil tank opening
Install the mounting 9. If the cab comes with the front guard, ship it with the wiper assembly attached
bolts, etc. on the to the cab.
Plug - 4 10. Install the parts contained in "bracket under the track" kit no. 9207237 to the bottom
opposite side.
of the track center frame (item numbers in *□ ).
O-ring - 4/8
There is no need
to remove the travel
To be fixed with wire
motor cover.
Procedure
Fig. 1
EX1200-6 (Backhoe front) +++++++
117
Detail B
2. Procedure (Loader front)
Wrap edges of the hose in vinyl bag

Plug - 2 and hold in place with wire, etc. Mirror assembly Mirror assembly Duct assembly in front of radiator Duct assembly in front of oil cooler
next to the fender next to the cab
Plug - 4
(To be installed to bottom as well)

(With rear camera) (With no rear camera)
Rear camera
Muffler cover Pipe, exhaust
※Refer to Note 9.
Antenna Wiper assembly - 2
(To be packaged separately in air bag cushioning material)
Install the mounting (Bolt, sems J271020)

bolts, etc. on the bolts, etc. on the For installing the rear camera - 4
opposite side. opposite side.
Rear camera harness Rear light harness
Step in front of cab Ascent/decent-use lamp assembly Lamp, head - 2 Box assembly
Install the mounting Install the mounting (Washer, plain 4338575) Install the mounting
(Bolt, sems J281225) Install the mounting
Install the mounting bolts, etc. on the bolts, etc. on the (Bolt J901402) bolts, etc. on the
bolts, etc. on the
bolts, etc. on the opposite side. opposite side. Duct mounting Duct assembly hinge opposite side.
opposite side.
opposite side. bolt, assembly - 8 mounting sems bolt - 8
(Clip 4190261) (Clip 4190261)
Gasket
Remove the electrically-mounted parts box from the cab Sheet~1 Cover with vinyl sheet so that the inside of the cab, For fixing the harness~13 For fixing the harness~11
ceiling and using a clip band, fix on top of the seat. air conditioner, etc. are not exposed to wind and rain. Install the evacuation tool box
Install the mounting bolts, etc. on the cab side. Leave mounting bolts to the cab. (Bolt, sems J271025) (Bolt, sems J271025)
Wrap this part in vinyl bag and Cover the front of the radiator and Only Russian specification - package
the harness connectors connected. secure with tape. Cover it with For fixing the harness~13 For fixing the harness~11
oil cooler with plywood. in wooden crate (robbery prevention).
sheet and fix with the rope that is
attached to the sheet. Then, fix Scrap the removed gasket and (Plywood mounting bolt J281235 - 12)
in place with wire. send out a new gasket.
Upper duct assembly Cab assembly
Handrail above the fuel tank Counterweight
Install the floor parts (right-hand
duct, cover, air intake filter, etc.)
Counterweight tightening inside the cab.
Cover (R)
washer - 8 (7059399) Cover the antenna with vinyl
Cover (L) bag, etc. (rust prevention).
(7059400)
Apply anti-rust lubricant.
Install the mounting Attach the pins. Install the mounting bolts, etc.
bolts, etc, on the
on the opposite side.
opposite side.
Bracket - 4
Washer - 8
Lower duct assembly
Handrail above the oil cooler Counterweight tightening bolt - 8
Bolt - 8
Side frame
Nut - 8
tightening bolt - 52
Apply anti-rust lubricant
(4 places). Upper structure, base machine Rear light - 2 Bracket - 2
Nut - 4
Side frame tightening Plug - 2 Install the mounting bolts, etc.

spacer - 52 Cap - 4 to the cab.
Frame, side (L)
Chain Step next to the battery cover Step next to the side frame - 2 Seat assembly
Frame, side (R) Plug - 2
O-ring - 4/8 Leave the seat belt installed to the seat.
Slide ladder Step
Install the seat mounting bolts, etc.
Bracket - 2
700mm shoe-use 900mm shoe-use on the opposite side.
Attach bolts to the handrail
Install the mounting Ladder - 2 Ladder - 2 coupling plate and then
bolts, etc. on the
Install the mounting (Bolt, sems J271225) install the plate.
opposite side.
Slide ladder-use bolts, etc. on the
Step opposite side. For installing the rear light - 6
bolts, etc. on the
Install the mounting opposite side.
bolts, etc. on the (Clip, band 4055312)
(Washer 4114405) (Washer 4114405)
opposite side.
(Washer, spring A590916) (Washer, spring A590916) For fixing the harness at rear light - 1
(Bolt J921655) (Bolt J921680)
Assembly bolt for installing Assembly bolt for installing (Clip, band 4259220)
the fender next to the battery the fender next to the cab - 6 Standard Full
box - 6 track guard track guard For fixing the harness at rear light - 2
Fender next to the hydraulic oil tank 700G shoe 1. This drawing shows how to disassemble EX1200-6 inside the factory for shipment.
Attach bolts to the handrail 900G shoe 2. Disconnect the minus side of battery body earth before disassembly.
- when the slide ladder is being used bolts, etc. on the
coupling plate and then 3. For covers, plugs and other such necessary parts for packaging, use those contained
opposite side.
install the plate. in the "base machine shipment parts" kit no. 9106314 (item numbers in □).
Install the mounting Install the mounting Fix the pilot hose 4. Cover the electric wire connectors with vinyl bag and fix in place with clip band or tape.
bolts, etc. on the Fender next to the hydraulic Fender next Fender next to the Install J901630 in place with a clip band. 5. Rust-proof around all bolts, frame coupling parts, screw holes, machined surface, etc.
bolts, etc. on the Fender next to the cab Install J901630
opposite side. oil tank - for standard to the engine battery box on the opposite side. Handrail next to the battery box 6. Grease up the track link and make it taut.
opposite side. Plug - 2 on the opposite side.
Install the mounting 7. For engine anti-freeze agent, use TES900-200.
bolts, etc. on the 8. After disassembly, replenish the base machine with hydraulic oil.
opposite side. Install the mounting Hydraulic oil level: up to the 100mm level from the hydraulic oil tank opening
Plug - 2
bolts, etc. on the 9. If the cab comes with the front guard, ship it with the wiper assembly attached to the cab.
opposite side. 10. Install the parts contained in "bracket under the track" kit no. 9207237 to the bottom
Attach bolts to the handrail
of the track center frame (item numbers in *□).
coupling plate and then
install the plate.
Plug - 4
O-ring - 4/8
There is no need to remove To be fixed in

the travel motor cover. place with wire
Procedure
Fig. 2
EX1200-6 (loader front) +++++++
119
MOUNTING PROCEDURE FOR

LOADER FRONT-END ATTACHMENT
ATTACHMENT
8. Mounting procedures for loader front
8-1 Preparation
ASSEMBLY CHART OF LOADER FRONT
Fig. 1
Step 1
Parts required
Linkage Assembly Bucket Assembly
Item Part No. Part name Q'ty Item Part No. Part name Q'ty
00 ─ Loader front 1 J ─ Bucket 1

01 ─ Boom cylinder 2 K 4245637 Shim 2
03 ─ Clamp assembly 1 L 4245638 Shim 2
05 ─ Clamp assembly 1 M 4487592 O-ring 2
07 ─ Clamp assembly 1
09 4439777 Hose 5
10 4439778 Hose 4
11 4704472 Hose 1
12 4704473 Hose 2
13 4296629 Hose 2
14 4697605 Hose 2
15 4454680 Hose 2
H 4510169 O-ring 8
I 4508805 O-ring 10
123
Step 2 Detail A
Preparation of the boom
1 1 Place wooden blocks under the boom (L/D front)

00 as shown in Figs. 2 and 3.
00
Wooden block: 2 pcs. Fig. 2
Size: 1 000 mm (L) × 500 mm (W) × 800 mm (H)
(40 in) (20 in) (30 in)
b
Note:
Each wooden block must be able to carry a load of a
at least 1 500 kg (3 300 lb).
2 Clean the pin holes a of the boom foot indicated
by .
Wooden block
3 Clean the pins b for the boom cylinder indicated Fig. 3
by . Detail B
4 Extract the pins b and spacer e , indicated by Wire rope
as shown in Figs 3 and 6. 10 mmø×
5 000 mm Wire rope
10 mmø×
2 Installation of the boom cylinders 2 000 mm
Lever block
1 Clean the pin holes c and d of boom cylinder 01 c
indicated by .
2 Attach wire ropes and a chain block to the boom 01 Wire rope
cylinder 01 as shown in Fig. 4. Boom cylinder 10 mmø×
2 000 mm
Boom cylinder 01 weight: 1 170 kg (2 575 lb)×2
d
Wire rope: 3 pcs.
Fig. 4
10 mmø × 5 000 mm (L) : 1 pc.
(0.4 inø) (195 in L)
10 mmø × 2 000 mm (L) : 2 pcs.
Lift & move
(0.4 inø) (78 in L)
Lever block: 1pc. b c

for 2 tonne (2.2 US ton) load
3 Lift the boom cylinder 01 as shown in Figs. 4 and
5.
4 Move the boom cylinder to the pin hole b
indicated by on the boom cylinder c .
3 Align the pin holes b and c indicated by for

inserting the spacer e . (Figs. 6 and 7.) Fig. 5
Detail C
Hold
b
Spacer e c
Boom cylinder
Outside Inside
Fig. 6
Fig. 7
124
4 1 Align the pin holes b and c indicated by
Hold
for inserting the pin.
Note:
Grease the pin before inserting. b
2 Tighten the pin with 2 bolts, 2 spring washers, 1 c
plate and 1 spacer.
Note:
Apply lubricant to the bolts before installing. D

Fig. 8
Section D
Plate
Bolt &
spring washer
Inside Outside
Pin
Spacer
e Boom cylinder
Fig. 9
Detail E
Lever block
Boom cylinder
5 1 Support the rod side of the boom cylinder, using Wire rope
10 mmø×
the lever block and wire rope as shown in Fig. 10. 3 000 mm Fig. 10
Lever block: 2 pcs.
for 1 tonne (1.1 US ton)
Take off the crane
wire ropes and
Wire rope: 4 pcs.
chain block
10 mmø × 3 000 mm (L)
(0.4 inø) (117 in L)
Shackles: 2, for 1 tonne (1.1 US ton)
2 Take off the crane wire ropes and chain block

lifting the boom cylinders. (Fig. 11)
Fig. 11
125
6 Connect the boom cylinder hoses 13 and 14 indicated a
by . (Fig. 12)
b
Tightening torque of hose 14 : 270 N·m

(18 kgf·m/135 lbf·ft) Boom cylinder hoses Fig. 12
Notes:
i) When connecting hoses, do not twist them, or
Detail F
their service life will be shortened.
ii) Connect the hoses so as not to make contact Hose 14 O-ring H
with other parts. O-ring H O-ring I
iii) Make sure that there is no dust sticking to the
seat faces of the hoses.
iv) Pay attention not to damage the joining surfaces
of the hoses. Hose 13
v) Use O-rings H (P/No. 4510169~2) and I
(P/No. 4508805~2) to install the hoses. Apply a O-ring I
thin layer of sealant #98D to the O-rings before
installation.
The other boom cylinder should also be installed in

the same manner as the above. Fig. 13
7 After the oil has run out, clean the parts carefully.
Fig. 14
8 Remove urethane foam sleeves c , fitted as protection Detail G

on the plated boom cylinder rods.
Plated
cylinder rod
Boom cylinder
Urethane
foam sleeve c
Fig. 15
126
9 1 Connect the grease hoses a indicated by . Detail H
Tightening torque of hose: 50 N·m

Notes:
ii) Connect the hoses so as not to make contact a
with other parts.
iii) Make sure that there is no dust sticking to the Boom cylinder

iv) Pay attention not to damage the joining surfaces Fig. 16
of the hoses.
The other grease hose should also be installed in

the same manner as the above.
Fig. 17
2 After the grease has run out, clean the parts

carefully.
10 Fix a clamp 07 at midpoint of the hoses with, bolts, Detail I

washers and nuts. 07
Note:
The clamp 07 is made of wood, and if tightened
excessively, it may break.
Tightening torque of M12 lock nut: 90 N·m

Fig. 18
Fig. 19
127
Step 3
Preparation of the loader bucket
1 1 Position loader bucket J as indicated in Fig. 20.

a
Bucket assembly J weight: 5.9 m 3
9 780 kg
(21 515 lb) b
6.5 m3 9 200 kg
(20 240 lb)
2 Clean pins a and b in bucket J .

3 Extract pins a and b from the bucket.
4 Clean pin holes a and b on the bucket.
Fig. 20
c 00
2 1 Remove cover c as shown in Fig. 21.
Fig. 21
2 Set pins a and b , previously removed from the View J

bucket, as shown in Fig. 22. M
a
3 Set the 2 O-rings M (4487592~2 pcs.) as shown
in Fig. 22.
Fig. 22
4 Apply grease to bucket pin holes d and e and View K

the connecting surfaces of the arm end (a total of d
8 locations) as shown in Fig. 23.
Fig. 23
128
3 Remove urethane foam sleeves a , fitted as protection
on the plated dump cylinder rod.
Detail L
Urethane Dump cylinder
foam sleeve a
Plated
cylinder rod Dump cylinder Fig. 24
Fig. 25
129
130
8-2 Mounting of loader front
Step 1
Mounting of the boom
1 1 Clean off the anticorrosive applied to the pins

inserted into the boom-jointing portion of the main
frame.
2 Extract the 2 pins a and b , indicated by ,
from the main frame.
3 Apply grease to the above-described pin holes.
Fig. 1
Detail A
b
a
Main frame
Fig. 2
2 1 Put shackles on the eye-plate provided on the
boom 00 , attach wire ropes and a chain block Detail B Lift
thereon as illustrated in Fig. 3.
2 Lift the boom so that the pin holes c and d Wire rope
22 mmø×
indicated by become horizontal. 3 000 mm
Wire rope
22 mmø×
Note: 10 000 mm
Level the boom by adjusting the preset chain blocks.
Chain block
CAUTION:
Wire rope
boom. 22 mmø× Shackle
3 000 mm
Loader boom 00 weight: 17 640 kg
(38 810 lb) Wire rope
Shackle 00
Wire rope: 5 pcs. d

22 mmø ×10 000 mm (L) : 1 pc. Shackle
(0.85 inø) (390 in L)
22 mmø × 3 000 mm (L) : 4 pcs.
(0.85 inø) (117 in L) Fig. 4 Fig. 3
c
Shackle: 3 pcs.
Lift
Chain block: 2 pcs.

c
b
Fig. 5
131
3 1 Lifting the boom, move it horizontally to the holes
a indicated by on the main frame.
2 Move the boom to the pin holes a indicated by Lift & move
on the main frame.
Notes: Cab
i) When moving the front, be

careful not to let it touch the
cab on the superstructure. a
ii) It is safe to attach a rope
★
on part indicated by ★
to guide it.
Rope
8 mmø×5 000 mm
Fig. 6
Rope: 1 pc.
8 mmø × 5 000 mm (L)
4 1 Align the pin holes a and b indicated by

for inserting the pins.
2 Grease the pins before inserting. C
Adjust a clearance between the frame and boom a

by reference to the instructions on pages 222 b
and 223.
5 Tighten the 2 pins with 4 bolts, 4 spring washers and 2

plates.
Fig. 7
Note: Section C
Apply a lubricant to the bolts before installing.

(40 kgf·m/290 lbf·ft) Pin
Plate
Bolt &
Spring
washers
Fig. 8
6 1 Place 1 wooden block c , about 200 mm (8 in) in

height, on the ground where the arm top is placed.
Lower Take off the crane wire ropes

Wooden block c : 1 pc.
and chain blocks
Size: 1 500 mm (L) × 300 mm (W) × 200 mm (H)
(59 in) (12 in) (8 in)
2 Lower the front so that the arm top rests on the

wooden block.
Wooden
block c
7 Take off the crane wire ropes and chain blocks lifting 200 mm (8 in) Fig. 9
the boom assembly.
132
Step 2
Hoses
Connection of the hoses to basic machine and boom
1 1 Before doing this work, do not forget to release

the pressure in the hydraulic tank.
2 Then remove the blind covers from the pipe ends.
Fig. 10
2 1 Connect the 5 hoses 09 and 4 hoses 10 to the
basic machine and boom.
Hose 09 , 10
Notes:
ii) Connect the hoses so as not to make contact
with other parts.
of the hoses.
(P/No. 4508805~4) to install the hoses. Apply a
installation.
Fig. 11
Tightening torque of hose 09 : 5 pcs. 180 N·m
(18 kgf·m/135 lbf·ft) Detail D

2 After the oil has run out, clean the parts

carefully.
Hose 09
O-ring I
Hose 10
Hose 09
O-ring H
O-ring I
Fig. 12
133
3 Fix a clamps 03 and 05 at midpoint of the hoses with,
bolts, washers and nuts.
Tightening torque of M12 lock nut: 90 N·m

Fig. 13
Detail E
03
05
Fig. 14
134
Step 3
Connection of the arm cylinder hoses.
1 1 Remove the blind covers from the pipe ends.
2 Connect the 3 hoses 11 and 12 to the pipings.
Notes:
i) When connecting hoses, do not twist them, or Arm cylinder hoses Fig. 15
Detail F
ii) Connect the hoses so as not to make contact Hose 12
with other parts. Hose 12 I
O-ring
Hose 11
iii) Make sure that there is no dust sticking to the O-ring I
seat faces of the hoses. O-ring H
of the hoses.
installation.
Tightening torque of hose 12 : 180 N·m Fig. 16


Level cylinder
2 1 Before shipping the loader front assembly, remove

the stoppers d and e which lock the level
cylinder to avoid its retraction.
3 Remove urethane foam sleeves f , fitted as
protection on the plated arm cylinder rod.
Fig. 17
Detail H Detail G
Urethane e
foam sleeve f
Arm cylinder
Plated d
cylinder rod
Fig. 19 Fig. 18
135
Boom cylinder
Step 4
Installation of the boom cylinder
1 1 Extract 2 pins from part b indicated by .

2 Carefully clean the pin holes a and b indicated a
by . b
Fig. 20
Detail I
d
d Level block
2 1 Lower the boom cylinder slowly with the lever

Boom cylinder
block d until the pin hole of the boom cylinder rod Boom cylinder (R)
a aligns with b indicated by on the main (L)
frame (Fig. 22).
Fig. 21
2 Start the engine and extend the rod end of the

boom cylinder.
a
b
Boom cylinder rod
3 1 Align the pin holes a and b indicated by Fig. 22

Note: b
Grease the pins before inserting.
a
2 Install the pin.
3 Tighten the 1 pin with 2 bolts, 2 spring washers
and 1 plate.
Note:
Fig. 23
Apply lubricant to the bolts before installing. Detail J
Pin
Section K
Pin Pin Fig. 24
Plate
Bolt &
Spring
washers
Fig. 25
a b
The other boom cylinder should also be installed in K
Fig. 26
136
4 Connect the grease hoses a and b indicated by
.

Notes:
their service life will be shortened Fig. 27
ii) Connect the hoses so as not to make contact Detail L
with other parts.
b
iv) Pay attention not to damage the joining surfaces Grease hose
of the hoses.
5 After the grease has run out, clean the parts carefully.
a
Fig. 28
137
Step 5 Detail M
Greasing (2)

grease gun.
a
automatically.
fitting and pull the gun lever; grease will be
IMPORTANT:
Run the engine at medium speed or more when b Fig. 29
2 Start the engine.
3 1 Supply grease 8 to points as shown in Figs. 30

and 31.
2 Supply grease 2 to points as shown in Figs. 32 Fig. 30
and 33.
Detail N
Notes:
BOOM CYL. BOTTOM
standard air grease gun. Grease up at the front BUCKET CYL. ROD
pins with the air grease gun manually. BUCKET CYL. ROD
BOOM CYL. BOTTOM
iii) Insufficient greasing will wear the pins. LEVEL CYL. BOTTOM
ARM CYL. BOTTOM
BOOM FOOT
BOOM FOOT Fig. 31
Detail O
BUCKET CYL.
ROD
Fig. 33
Fig. 32
138
4 Lubrication method

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
taken, as follows:
● Tip nozzle
f
f a little so as to release the connecting
b

at this time.
g
Note:
hose.
h
Fig. 36
139
CAUTION:
Extend
Do not operate any cylinders of the front before
attaching the bucket at this time, because if the Ralse
cylinders are accidentally operated, the bucket cylinder
which is suspended by a shackle on the arm may be
Retract
forced to move resulting in serious failure or injury.
Lower
Fig. 37
CAUTION!
Fig. 38
140
8-3 Mounting of bucket
Step 1
Setting of the bucket cylinders
Fig. 1
CAUTION:
Never extend or retract the bucket cylinder rod when
Detail A
removing the eye bolts a .
Eye bolt a
Otherwise, the eye bolts will be broken, leading to
serious trouble.
Bucket cylinders
Fig. 2
Detail B
Chain block
Fig. 3 Wire rope

10 mmø×
2 000 mm
1 Hold the bucket cylinders with chain blocks or cranes. b Shackles

c Eye bolt
Wire rope: 2 pcs.
10 mmø × 2 000 mm (L)
(0.4 inø) (78 in L)
Chain block: 2 pcs. Wire rope

for 2 metric ton (2.2 US ton) load 10 mmø×2 000 mm Fig. 4
Bucket cylinder weight: Approx. 500 kg

(1 100 lb) Detail C
Chain block
2 1 Lift the bucket cylinders a little with chain blocks.
2 Take out the shackles b indicated by .
3 Remove the eye bolts c from the bucket
cylinders.
b
3 Move the bucket cylinder toward the arm with the chain
block as shown in Fig. 5.
c
Fig. 5
141
Step 2
Mounting of the bucket
1 1 Extract 4 pins a and b from the bucket L

a
c
Indicated by . L
2 Clean the parts a , b , c and d indicated by
.
3 Apply grease to the parts a , b , c and d d
b
indicated by . Fig. 6
F
4 Set the O-rings M as shown in Fig. 7.
Lift
Section F
Detail D Lift
Wire rope
26 mmø×
Detail E 2 000 mm
Outside Inside Wire rope

26 mmø×
O-ring 8 000 mm
Fig. 7 M Chain
block
Wire rope
2 1 Putting shackles on the eye plates provided on the
bucket L , attach wire ropes and chain block onto
the shackles. Shackle
2 Lift the bucket as illustrated in Figs. 8 and 9. Wire rope
26 mmø×
2 000 mm
Bucket G weight:
5.9 m3 : 9 780 kg (21 515 lb)
Shackle
6.5 m3 : 9 200 kg (20 240 lb)
Fig. 8
Wire rope: 3 pcs.

26 mmø × 2 000 mm (L) : 2 pcs. Fig. 9
26 mmø × 8 000 mm (L) : 1 pc.
(1.0 inø) (312 in L)
Shackle: 2 pcs.
Arm
Chain block: 1 pc.
a
1 300 mm
(50 in)
Fig. 10
3 Raise the arm top 1 300 mm (50 in) above the Lift & move
ground.
4 Lift the bucket so that the pin holes a indicated
by become horizontal.
a c
5 Move the bucket to the pin hole c indicated by

on the arm top.
Fig. 11
142
Lift
3 1 Align the centers of the pin holes a and b
indicated by for inserting pins.
2 Install the pins.
Apply grease to the pins before inserting. a
b
Note:
At this time, if there is a gap between the arm and
the bucket, insert shims K and L as shown in Fig.
13. G
Fig. 12
Section G
Adjust a clearance between the boom and bucket
by reference to the instructions on pages 222
and 223.
O-ring M
Shim Fig. 13
K L
Detail H
3 Check the O-rings M as shown in Fig. 13.
Stopper
Note:
The O-ring is placed at the boss of the bucket as
Pin
shown in Fig. 13.
4 Tighten the 2 pins with 6 bolts. 6 spring washers

and 2 stopper.
Bolt &
Note: spring
Fig. 14 washer
Apply lubricant to the bolts before installing.

5 After inserting the pins, position the O-rings M in

Arm
the groove. (Fig. 15)
O-ring M Fig. 15
Section I
Lower
4 1 Lower the bucket with a crane so that bottom of

the bucket will be on the ground.
Fig. 16
Take off the crane wire ropes
and chain blocks
2 Take off the crane wire ropes and chain blocks

lifting the bucket.
Fig. 17
143
Step 3
Extend the bucket cylinders to align its pin bucket pin
holes for inserting the pins.
1 Extend the bucket cylinders in the direction of the arrow

" " to align the centers of the bucket cylinder's Bucket cylinder
bottom pin holes a indicated by and the

bucket pin holes b indicated by as shown in
a
Fig. 18.
Fig. 18
b
Detail J
Note:
Align the pin hole ( b ) on the bucket and Chain block
the bucket cylinder bottom pin hole ( a ) by
operating the chain block supporting the bucket
cylinder.
b
Fig. 19
2 1 Align the centers of the pin holes a and b of the

bucket cylinders and bucket.
2 Grease the pins, before inserting.
3 Insert the pins in the pin holes a and b indicated
by .
Bucket cylinder
a b Fig. 20
3 Fix the 2 pins with 6 bolts, 6 spring washers and 2

stopper.
Note:
Tightening torque of M16 bolt: 270 N·m K Fig. 21

Section K
Stopper
4 Take off the chain blocks holding the bucket cylinders.

Bolt &
spring
washer
Pin
Fig. 22
144
Step 4
Connection of the dump cylinder (open/close) hoses and
grease hoses
1 1 Prior to the connection of the hoses, release the

air pressure in the hydraulic tank.

Fig. 23
Detail L
2 1 Connect the end of the 2 hoses a to the pipe end

of the arm indicated by .
Tightening torque of hose a : 180 N·m

Width across flats: 12 mm O-ring I
2 After the oil has run out, clean the parts carefully. a
Notes:
Fig. 24
with other parts. Detail M
of the hoses. c
v) Use O-rings I (P/No. 4508805~2) to install the b
hoses. Apply a thin layer of sealant #98D to the
Bucket
O-rings before installation. cylinder
3 Connect the 2 grease hoses b and c indicated

by .
Tightening torque of hose b and c : 35 N·m

(3.5 kgf·m/26 lbf·ft)

Fig. 25
carefully.
3 Close the air-vent cock on the hydraulic tank.
Detail N
4 Check that all the tightening bolts at the loader front are
securely tightened.
Fig. 26
145
Step 5 Detail O
Greasing (3)

grease gun.
automatically.
a
IMPORTANT:
supplying grease using the lubricator. b Fig. 27
Detail P
2 Start the engine.
BUCKET AND ARM JOINT PIN

BOOM AND ARM JOINT PIN
ARM CYL. ROD
3 1 Supply grease to 8 points as shown in Figs. 28 LEVEL CYL. ROD
and 29. BOOM AND ARM JOINT PIN
BUCKET AND ARM JOINT PIN
2 Supply grease to 6 points as shown in Figs. 30 BUCKET CYL. BOTTOM
BUCKET CYL. BOTTOM Fig. 28
and 31.
Notes:
standard air grease gun. Grease up at the front
Q
iii) Insufficient greasing will wear the pins.
Fig. 29
Detail R View Q
BACKET BACKET
LEFT SIDE RIGHT SIDE
1 2 3 3 2 1
BACKET BACKET
HINGE PIN HINGE PIN
DUMP CYLINDER DUMP CYLINDER
ROD PIN ROD PIN Left side Right side
DUMP CYLINDER DUMP CYLINDER
BOTTOM PIN BOTTOM PIN
Fig. 31 Fig. 30
146

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
taken, as follows:
f
b

at this time.
g
Note:
hose.
h
Fig. 34
147
Step 6
Air bleeding for cylinders
Raise
1 1 Start the engine. Extend
Tilt-in
CAUTION: Open/Close Lower

Retract
Make sure that nobody other than the operator is in or Tilt-out
on the hydraulic excavator.
Fig. 35
2 Idle the engine sufficiently to release the air in the
hydraulic system.
3 Check for unusual vibration or noise.
4 Operate each cylinder a few times to bleed the air
in the hydraulic system, according to the following
procedure.
Note:
The engine speed should be kept as low as
possible.
2 Procedure
Action
1 Start the engine.
Note:
Run the engine at low speed.
2 Move each cylinder back and forth five times.
Notes:
i) Avoid moving the cylinder suddenly or quickly, or
the seals may be burnt.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end during the first four cycles.
iii) Move the cylinder at full stroke on the fifth cycle.
3 Hold the cylinder at the stroke end for a minute to

apply relief pressure and bleed the air from the
cylinder. Repeat the procedure twice.
4 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air (Refer to next page)
148
Step 7
Bleeding locations
CAUTION:
Take all reasonable precautions as this work is to be conducted high above the ground.
1 1 Set the front-end attachment on the ground as illustrated below (Fig. 35).
2 Stop the engine.
CAUTION:
Take care to prevent anybody from starting the engine during the work.
3 Follow the procedures outlined below to release air from the cylinders, by way of each of the
bleeders indicated by .
1) Remove the rubber cap.

2) Loosen the plug.
3) A mixture of air and hydraulic air will escape from the
bleeder.
4) Continue bleeding until only oil escapes.
5) Tighten the plug securely.
6) Replace the rubber cap.
Boom cyl.
Level cyl. Level cyl.
Arm cyl.
Arm cyl.
Bucket cyl.
Boom cyl.
Bucket cyl.
Fig. 36
Detail S
Level check
2 Recheck the oil level in the hydraulic tank. If the oil
level is low, refill the tank.
Fig. 37
149
Step 8
Adjusting of the stoppers
＊ Operate the bucket as shown in Figs. 37 and 38, and

check for contact between the arm and bucket
stoppers.
Detail T
1 Bucket roll-out stoppers on the arm and bucket
must contact each other over more than 20% of
their surface areas. (Fig. 38)
Arm stopper
Bucket stopper
Fig. 38
2 Bucket roll-in stoppers on the arm and bucket

must contact each other over more than 20% of Detail U
their surface areas. (Fig. 39)
Bucket stopper
Arm stopper
Fig. 39
Note:
If the contact between the stoppers is insufficient,
use a grinder to modify the stopper shape, making
the surfaces flat and smooth.
Fig. 40
150
8-4 Adjustment of track link tension
Swing upperstructure 90° and lower bucket to raise track off

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

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

Fig. 3
2 To tighten track, connect a grease gun to the
grease fitting a an add grease until the sag is Detail B
within recommended limits.
a Fitting
3 To loosen track turn valve b counterclockwise
slowly (use long socket 24). Grease will drain from
CAUTION!
Never touch
grease outlet with valve b loosened 1 to 1.5 turns.
If grease does not drain smooth, slowly rotate the
track with it raised off the ground.
b Valve
Be sure to retighten valve b to 88 N·m
(9 kgf·m/65 lbf·ft) after loosening track.
Grease outlet
Fig. 4
IMPORTANT: Detail C
It is abnormal if track is still tight after turning valve b
counterclockwise or track is still loose after charging
grease to fitting a . In such cases, NEVER
DISASSEMBLE the track adjuster. See your authorized
dealer immediately.
Fig. 5
151
152
8-5 Final trial operation check
1 After connecting all the hoses, check that no hose hits Detail A
against other hose or parts.
2 1 Adjust the track link tension to an appropriate

figure. (See page 151, "Adjustment of track link
tension.")
2 Check all functions of the machine. (See "Checks

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

oil is low, refill the tank through the oil filler port.
CAUTION:
Before starting the excavator, make sure there is no
person other than the operator in or on the machine.
Fig. 1
Note:
After the above procedures are completed, work at
60% to 70% power for the first 50 hours of
operation, and then begin full-power operation.
Forward Reverse
travel travel
Right Swing
Swing
Left
Forward Reverse
travel travel
Fig. 2
Raise
Extend
Tilt-in
Open
Lower
Close Retract
Tilt-out
Fig. 3
153
1. Procedure, loader front •••••••••••••••••••••••••••••••••••••••••••••• 155
2. Procedure, bucket •••••••••••••••••••••••••••••••••••••••••••••• 157
154
Detail A
1. Procedure, loader front

Hose ~2 Hose ~2
Hose ~5
Hose ~2
Hose ~4
Hose ~1
Apply anti-rust lubricant to the pin.

Hose ~2
Cover ~2
Loader front ~1
Cover ~4
Cover ~5
Cover ~2
Apply anti-rust lubricant to the inner

surface and along its edges.
Nut ~4
Spring washer ~4
Stopper ~1
Plain washer ~4
Cover ~2 Rubber ~2
Cover ~2 Stopper ~2
Cover ~1 to the inner surface and
along its edges.
Urethane foam

to the inner surface and
along its edges. [Upper structure side]
Cylinder, boom ~2
Clamp assembly ~1
1. This drawing shows the transport-posture of EX1200-6 loader front.
☆
2. Parts at ○ are those contained in kit no. 9304370 (packing parts).
3. Rust-proof around exposed pins, machined surfaces and plated parts
Plated part of the cylinder rod.
of the cylinder rod 4. Apply anti-rust lubricant to the plated parts of the cylinder rod,
wrap urethane foam around the rod and hold in place with vinyl-coated wire.
Wrap the rod excessively Use anti-rust lubricant which consists of 7:3 mixture of hydraulic oil and grease.
up to the cylinder tube.
Apply anti-rust lubricant [Between the boom and arm]
Rust proofing of cylinder rod to the inner surface and
[Boom side]
Clamp assembly ~1 Clamp assembly ~1
along its edges.
Procedure,
Fig. 1
EX1200-6 loader front +++++++
155
Detail B
2. Procedure, bucket (Bushing)

(Bushing)
(O-ring) (Pin)
(Bolt)
(Bushing)
(Washer, spring)
ia.
(Bolt, socket)
Pin d
(Bolt, sems) (Pin)
Stopper A
(Stopper)
(Plate, lock)
(Cover)
Pin dia
Cylinder center
(Shim) DETAIL a
.
Hose center (Pin)
(Shim) (Bushing)
(Screw, drive)
(Nameplate) (O-ring)
SECTION C (Seal, dust)

(Bushing)
(Cylinder, dump) (Bushing)

(Shim)
(Stopper)
VIEW I (Cylinder, dump)
(Bolt M16×40)
(Pin) (Stopper)
(Shim)
(Washer, spring M16)

SECTION A
(O-ring 1BP18)
Pin dia.
(Bolt, sems)
(Spacer)
(Bucket, rear)
(Cover)
SECTION B
(Bolt M12×25)
(Bolt, socket)
(Washer, spring)
(Flange, split)
(Cover)
(O-ring)
(Bolt M12×25)
(Washer, spring)
(Hose) Stopper B
For hose installation

direction, see VIEW I.
(Hose)
(Block)
(Bolt, sems)
SECTION E (Bucket, front)
(Cover)
(O-ring)
(Flange, split)
(Bolt, socket) (Bolt)
1876 (bucket opening depth) (Apply Loctite 242)
(Point, tooth)
(Plate)
(Plug)
(Pin, lock)
(Rubber)
(Rubber, lock) 1. For 95 , refer to 9201749 (auto lubrication, bucket).

(Bushing) 2. Adjust shims 23 , 24 , 48 , 49 so that the spaces between the left and right are equal.
(Bolt, sems) (Bushing) 3. After covering with 85 , 86 and 87 seal with TECTYL 859 and store in the warehouse.
4. The imprinting on the nameplate is as follows.
(Bolt)
VIEW F Model : EX1200-6
Front No. : In accordance with instructions from the large-sized machine business dept.
(Washer, spring) Capacity : 6.5 m3
(Cover) SECTION G 5. Use a jig to adjust stopper A so that the left and right surfaces contact at the same time.
If there is an area that is not in contact, adjust with grinder so that the maximum space
(Rubber) is within 4 mm.
(Pin) (Stopper)
(O-ring) 6. Use a jig to adjust stopper B so that the left and right surfaces contact at the same time.
(Plate)
(Bolt)
VIEW H (For storage) (Bolt, sems)
SECTION D
Procedure,
Fig. 2
EX1200-6 bucket +++++++
157
MOUNTING PROCEDURE FOR

BACKHOE FRONT-END ATTACHMENT
ATTACHMENT
9. Mounting procedures for backhoe front
9-1 Preparation
ASSEMBLY CHART OF BACKHOE FRONT
Fig. 1
Step 1
Parts required
00 ─ Boom 9.0 m 1 9.0 m

00 ─ BE Boom 7.55m 1 7.55 m
02 4665310 Boom cylinder 2
03 ─ Clamp assembly 1 Base machine to boom pipings
04 ─ Arm 3.6 m 1 3.6 m
04 ─ BE Arm 3.4 m 1 3.4 m
06 ─ Clamp assembly 1 Base machine to boom pipings
08 4690042 Hose 1
For STD. boom (9.0 m)
09 4690039 Hose 2
08 4673718 Hose 1
For BE boom (7.55 m)
09 4673719 Hose 2
11 4485883 O-ring 2
12 4487692 O-ring 2
14 4439777 Hose 5
15 4439778 Hose 5
16 4454786 Hose 2
For STD. boom (9.0 m)
17 4690038 Hose 2
16 4604857 Hose 2
For BE boom (7.55 m)
17 4673716 Hose 2
P 4508805 O-ring 8
Q 4510169 O-ring 9
R ─ Bucket 5.20 m3 1
R ─ Bucket 6.70 m3 1
161
Step 2 Detail A
Preparation of the boom
1 1 Place wooden blocks under the boom 00 as

shown in Figs. 2 and 3.
Boom 00 weight: STD. 9.0 m 12 500 kg (27 500 lb)

Fig. 2
BE 7.55 m 11 500 kg (25 300 lb)
Wooden block: 2 pcs. 00

Size: 1 000 mm (L) × 500 mm (W) × 800 mm (H)
(40 in) (20 in) (30 in)
b
2 Clean the pin holes a of the boom foot indicated
by .
a
3 Clean the pins b for the boom cylinder indicated
by .
Wooden block
4 Extract the with spacer e pins b , indicated by
as shown in Fig. 6. Fig. 3
Detail B
2 Installation of the boom cylinders 02 Wire rope
10 mmø×
1 Clean the pin holes c and d of boom cylinder 02 5 000 mm Wire rope
indicated by . 10 mmø×
2 000 mm
2 Attach wire ropes and a chain block to the boom c Chain block
cylinder 02 as shown in Fig. 4.
Boom 02 cylinder weight: 1 130 kg (2 485 lb) × 2

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

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

5.
02
4 Move the boom cylinder to the pin hole f
indicated by on the boom.
3 Align the pin holes b and c indicated by for

inserting the spacer e .
Detail C Fig. 5
b f
Hold
Boom b
cylinder c
Spacer e
Outside Inside Fig. 6
Fig. 7
162
Hold
4 1 Align the pin holes a and b indicated by a
for inserting the pin. b
Note:
Grease the pin before inserting. D
2 Tighten the pin with 2 bolts, 2 spring washers, 1

plate and 1 spacer.
Note:
Tightening torque of M20 bolt: 400 N·m Fig. 8

(40 kgf·m/290 lbf·ft) Section D
Bolt & Boom cylinder
spring
washer
Plate
Outside Inside
Pin
5 1 Support the rod side of the boom cylinder, using
Spacer
the lever block and wire rope as shown in Figs. 10
e
and 11. Fig. 9
Lever block: 2 pcs. Detail E

Wire rope: 4 pcs. Lever block

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

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

wire ropes and
chain block
Fig. 11
163
6 Connect the boom cylinder hoses 16 and 17 indicated
a
by . (Fig. 12 and 13)

(27 kgf·m/200 lbf·ft) b

(18 kgf·m/135 lbf·ft) Boom cylinder hoses
Fig. 12
Notes:
Detail F
with other parts.
seat faces of the hoses. O-ring Q
iv) Pay attention not to damage the joining surfaces O-ring Q

Hose 17 O-ring P
of the hoses.
v) Use O-rings Q (P/No. 4510169~2) and P
installation. Hose 16
The other boom cylinder should also be installed in O-ring P
Fig. 13
164
8 1 Connect the grease hoses a indicated by . Detail G

Notes: a
with other parts. Boom cylinder
seat faces of the hoses. Fig. 14
of the hoses.
The other grease hose should also be installed in

2 After the grease has run out, clean the parts Fig. 15
carefully.
9 Remove urethane foam sleeve b , fitted as protection Detail H

on the plated boom cylinder rods.
Plated
cylinder rod
Boom cylinder
Urethane
foam sleeve b
Fig. 16
165
10 1 Connect the 1 hose 08 and 2 hoses 09 to the
boom piping.
Notes:
i) Make sure that there is no dust sticking to the
O-ring P
ii) Pay attention not to damage the joining surfaces
of the hoses.
09
iii) Use O-rings Q (P/No. 4510169~2) and P O-ring Q
thin layer of sealant #98D to the O-rings before 08
installation.
09
Tightening torque of hose 08 : 1 pc. 180 N·m
Fig. 17
Tightening torque of hose 09 : 2pcs. 270 N·m

2 Leave the free end of the installed hoses covered.

Arm cylinder
3 After the oil has run out, clean the parts
carefully.
11 Secure the arm cylinder rod with wire ropes and a lever
block, as shown in Figs. 18 and 19. Fig. 18
Wire rope: 2 pcs. Detail I

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

for 3 metric tonne (3.3 US ton) load
Wire rope
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being extended. Be
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident.
Fig. 19
Note: Detail J
The lever block secure the arm cylinders and Urethane
prevent the cylinder rods from extending during the foam sleeve a
work. Arm cylinder
12 Remove urethane foam sleeve a , fitted as protection

on the plated arm cylinder rod.
Plated
cylinder rod
Fig. 20
166
Step 3
Preparation of the arm 04
1 Place wooden blocks under arm 04 as shown in Fig.

20.
Arm 04 weight: STD. 3.6 m 6 130 kg (13 485 lb)

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

Size: 500 mm (L) × 1 000 mm (W) × 500 mm (H) Wooden
block
(20 in) (40 in) (20 in)
Note:
Each wooden block must be able to carry a load of Fig. 21
at least 3 500 kg (7 700 lb).
2 1 Clean off the anticorrosive from the pins a and

b inserted into the arm top. Bucket cylinder
2 Extract the pins a and b from the arm top.
3 Clean pin holes a and b . c
4 Clean off the anticorrosive applied to the pins c
b
inserted into the arm.
5 Remove grease hoses attached to pins c .
6 Extract pins c from the arm. a
7 Clean pin holes c and d in the arm.
d
Fig. 22
3 Remove urethane foam sleeve e , fitted as protection Detail K

on the plated bucket cylinder rod. Urethane
foam sleeve e
Bucket cylinder
Plated
cylinder rod
Fig. 23
167
4 Fix bucket cylinder rods with wire ropes and a lever
block as shown in Figs. 24 and 25. Bucket cylinder
Wire rope: 2 pcs.

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

for 3 metric tonne (3.3 US ton) load
CAUTION:
Securing this wire rope and lever block in place
prevents the cylinder rods from being extended. Be Fig. 24
sure to secure them, otherwise the cylinder may be
extended suddenly, causing a serious accident. Detail L
Wire rope
Lever block
Note:
The lever blocks secure the bucket cylinders and Wire rope
prevent the cylinder rods from extending during the
work.
Bucket cylinder
Fig. 25
168
Step 4 a x4
b x4
Preparation of the bucket
1 1 Position bucket R . R
Bucket N weight: 5.20 m3 4 910 kg (10 800 lb)

6.70 m3 6 650 kg (14 630 lb)
2 Clean pin holes a x4 and b x4, as shown in Fig.

26.
Fig. 26
2 Reinstall the pins a and b removed from the arm, as View M

shown in Fig. 27.
Pin a
Pin b
Fig. 27
3 Apply grease to the bucket pin holes and the

connecting surfaces of the arm end and link View N
Apply grease
(a total of 8 locations).
Apply grease
Fig. 28
169
170
9-2 Mounting of backhoe boom
Step 1
Mounting of the boom
1 1 Clean off the anticorrosive applied to the pins

inserted into the boom-jointing portion of the main
frame.
2 Extract the 2 pins a and b indicated by ,
from the main frame. Fig. 1
3 Apply grease to the above-described pin holes.
Detail A
b
Detail C a
Chain block
Wire rope
Wire
rope
Main frame
Fig. 2
Detail B
f Lift
e Wire rope
22 mmø×
Fig. 4 3 000 mm
Chain block
Wire rope
2 1 Put on the boom, attach wire ropes and a chain 22 mmø×
10 000 mm
block to boom 00 as illustrated in Figs. 3 and 4.
Note: Wire rope

22 mmø×
Apply protectors to part e and f indicated by . 3 000 mm
00
2 Lift the boom so that the pin holes c indicated by
become horizontal.
Note: c
Level the boom by adjusting the preset chain blocks.
CAUTION: Fig. 3
Lift
boom. c
STD. boom 00 weight: 14 760 kg (29 520 lb)

BE boom 00 weight: 13 760 kg (30 270 lb)
Wire rope: 4 pcs.

22 mmø ×10 000 mm (L) : 2 pcs.
(0.85 inø) (390 in L) c
22 mmø × 3 000 mm (L) : 2 pcs.
(0.85 inø) (117 in L)
Chain block: 1 pc.

Protector: 3 pcs.
Fig. 5
171
Lift & move
3 Lifting the boom, move it horizontally to the holes a
indicated by on the main frame.
Cab
Notes: b a
i) When moving the front, be careful not to
let it touch the cab on the superstructure.
ii) It is safe to attach a rope on part
indicated by ★ to guide it. ★
Rope
Rope: 1 pc. 8 mmø×5 000 mm
8 mmø × 5 000 mm (L)
(0.3 inø) (195 in L)
Fig. 6
Lift
D
4 1 Align the pin holes a and b indicated by a
for inserting the pins. b
2 Grease the pins before inserting.
Adjust a clearance between the frame and boom

by reference to the instructions on pages 222
and 223.
5 Tighten the 2 pins with 4 bolts, 4 spring washers and 2

plates.
Fig. 7
Section D
Note: Boom
Tightening torque of M20 bolt: 400 N·m Pin

Plate
Bolt &
spring
washer
Fig. 8
6 1 Place 1 wooden block c , about 200 mm (8 in) in

height, on the ground where the arm top is placed.
Wooden block c : 1 pc. Take off the crane wire ropes

size: 1 000 mm (L) × 300 mm (W) × 200 mm (H) and chain blocks
(40 in) (12 in) (8 in)
2 Lower the front so that the arm top rests on the

wooden block.
c
7 Take off the crane wire ropes and chain blocks lifting Wooden
the boom assembly. block
200 mm (8 in)
Fig. 9
172
Step 2
Connection of the hoses to basic machine and boom
Hose 14 , 15
1 1 Before doing this work, do not forget to release
the pressure in the hydraulic tank.
2 Connect the 5 hoses 14 and 5 hoses 15 to the basic

machine and boom.
Notes:
with other parts.
Fig. 10
iv) Pay attention not to damage the joining surfaces Detail E
of the hoses. O-ring P
v) Use O-rings Q (P/No. 4510169~5) and P Hose 15
installation.


Hose 14
O-ring Q
Fig. 11
173
3 Fix a clamps 03 and 06 at midpoint of the hoses with
rubber, bolts, washers and nuts.
Tightening torque of M12 lock nut : 90 N·m

Fig. 12
Detail F
03
06
Fig. 13
4 Close the air-vent cock on the hydraulic tank. After

the oil has drained, clean the parts carefully.
174
Step 3 Boom cylinder
Installation of boom cylinders
1 1 Extract 2 pins from part a indicated by .

2 Carefully clean the pin holes a and b indicated b
by .
3 Apply grease to parts a and b indicated by a
.
Fig. 14
Detail G
c
Lever block
Boom cylinder
Boom cylinder (R)
(L)
Fig. 15
2 1 Lower the boom cylinder slowly with the lever

block c until the pin hole of the boom cylinder rod
b aligns with a indicated by on the main
frame (Figs. 15 and 16).
a
2 Start the engine and extend the rod end of the b

boom cylinder.
Fig. 16
175
3 1 Align the pin holes a and b indicated by
b
Note: a
Grease the pins before inserting.
Adjust a clearance between the frame and boom

cylinder by reference to the instructions on
pages 222 and 223. Fig. 17
Detail H
2 Tighten the 1 pin with 2 bolts, 2 spring washers

and 1 plate.
Pin
Note:
Pin
Tightening torque of M20 bolt: 400 N·m Fig. 18
a b
Fig. 19
I
Section I
Pin
Plate
Bolt &
spring
washer
Fig. 20
The other boom cylinder should also be installed in

176
4 Connect the grease hoses a and b indicated by
.

Notes:
their service life will be shortened
Fig. 21
with other parts.
Detail J
seat faces of the hoses. Boom cylinder
iv) Pay attention not to damage the joining surfaces b
of the hoses.
Grease hoses
5 After the grease has run out, clean the parts carefully.
Fig. 22
6 Remove the lever blocks used to fix the arm cylinder in

"Step 2- 11 " on page 166. Arm cylinder
Fig. 23
Detail K
Wire rope
Lever block
Wire rope
Fig. 24
177
Step 4
Detail L
Greasing (2)
1 The machine is provided with a electrially operated

grease gun.
automatically.
(3) Connect grease gun a to the desired grease a
IMPORTANT:
b Fig. 25
2 Start the engine.
3 1 Supply grease to 2 points as shown in Figs. 26

and 27.
2 Supply grease to 5 points as shown in Figs. 28
and 29.
Notes:
i) When using a lubricator, increase the engine Fig. 26
speed above medium speed. Detail M
iii) Insufficient greasing will wear the pins. BOOM CYL.
ROD
Fig. 27
Detail N
BOOM CYL. BOTTOM

ARM CYL. BOTTOM
Fig. 28
BOOM CYL. BOTTOM

BOOM FOOT
BOOM FOOT
Fig. 29
178

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
taken, as follows:
f
b

at this time.
g
Note:
hose.
h
Fig. 32
179
Step 5
Raise
Air bleeding of boom and arm cylinders
Lower
CAUTION:
Make sure that nobody other than the operator is in or

hydraulic system.
in the hydraulic system, according to the following Fig. 33
procedure.
Retract
Note:
Extend
possible.
2 Procedure
Action
Fig. 34
1 Start the engine.
Note:
Notes:

4 Stop the engine.
180
3 Bleeding locations
CAUTION:
4 1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION:

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

Boom cylinder
from the bleeder.
Boom cylinder
6) Replace the rubber cap. Arm cylinder
Fig. 35
Detail O
Fig. 36
Detail P

level is low, refill the tank. Level check
Fig. 37
181
182
9-3 Mounting of arm
Step 1
Installation of the arm a
1 1 Clean off the anticorrosive b

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

Detail B
Detail A
3 1 Put shackles on the eye-plates provided for lifting Lift
Wire rope
the arm 04 and attach wire ropes to the shackles.
(Figs. 3, 4 and 5) Shackle
Detail C
STD. Arm 04 weight: 3.6 m 6 130 kg (13 485 lb) Wire rope
BE Arm 04 weight: 3.4 m 6 480 kg (14 255 lb) 26 mmø×
Wire rope
8 000 mm
Eye plate
Shackle: 2 pcs. Fig. 3
for 5 tonne load (5.5 US tonne load) Shackle
Wire rope: 2 pcs.

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

become horizontal.
c
Note: Fig. 5
Level the arm by adjusting the preset Lift
chain blocks.
CAUTION:
Never allow anybody to stand directly
beneath the lifted arm.
Fig. 6
183
4 1 Lift the arm as shown in Fig.7.
2 Move it to the pin hole a , indicated by Lift & move
of the boom end.
Note:
It is safe to attach a rope on part
indicated by ★ to guide it.
Wire rope: 1 pc.
8 mmø × 5 000 mm (L) b a
★
(0.3 inø) (195 in L)
Rope
8 mmø × 5 000 mm
Fig. 7
Hold
5 1 On the scaffoldings provided, align the pin holes
a and b indicated by for inserting the
pin.
2 Thereafter, do the work around the parts a and
b indicated by on the scaffoldings.
D
3 Grease the pin before inserting.
CAUTION:
Handle the pin with the utmost care since it is quite a b
heavy.
Scaffolding
Pin weight: 177 kg (390 lb)
4 To prevent the pin from coming out, attach it with

Fig. 8
2 bolts, 2 spring washers and 1 plate.
Section D
Note:
Plate

Bolt &
Width across flats: 30 mm spring
washer
CAUTION:
Pay full attention to safety since the work is done at a Pin
high place.
Fig. 9
6 1 Place a wooden block on the ground where

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

size:
1 000 mm (L) × 300 mm (W) × 200 mm (H)
(40 in) (12 in) (8 in)
200 mm
(8 in)
Fig. 10
184
7 Connect the arm cylinder Detail E
Lift
1 Attach wire ropes to the arm cylinder. Wire rope
8 mmø ×
5 000 mm
Wire rope: 2 pcs. each being
8 mmø × 5 000 mm (L) Arm cylinder
(0.3 inø) (195 in L)
2 Hold the arm cylinder with a crane. Fig. 11

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

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

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

Fig. 15
185
10 1 Prior to the connection of the hoses, release the Detail G
air pressure in the hydraulic tank.
3 Connect the hydraulic hose for the bucket cylinder
at part 08 and 09 indicated by . Hose 08
Hose 09
Notes:
ii) Connect the hoses so as not to contact other
parts.
seat faces of the hoses. Fig. 16
of the hoses.
v) Use O-rings Q (P/No. 4510169)~1 and P
(P/No. 4508805)~2 to install the hoses. Apply a
installation.
Tightening torque of hose 08 : 1 pc. 180 N·m


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

Fig. 17
Detail H
11 Remove the lever blocks used to fix the bucket cylinder
in "Step 3- 4 " on page 168. Wire rope
Lever block
Wire rope
Bucket cylinder
Fig. 18
186
12 1 Connect grease hose to parts a indicated by Detail I
.
a
2 Connect grease hoses at part b and c indicated
by .
Tightening torque: 50 N·m

c
Notes: b
with other parts.
iv) Pay attention not damage the joining surfaces of
the hoses.
Fig. 19

carefully.
Fig. 20
187
Step 2 Detail J
Greasing (3)

grease gun.
automatically. a
IMPORTANT:
2 Start the engine.
3 Supply grease to 4 points as shown in Figs. 22 and 23.
Notes:
iii) Insufficient greasing will wear the pins.
Fig. 22
Detail K
ARM CYL. ROD PIN

BUCKET CYL. BOTTOM PIN
(RIGHT)
(LEFT)
Fig. 23
188

grease gun b .
e
IMPORTANT:


IMPORTANT:
g
taken, as follows:
f
Tip nozzle f a little so as to release the connecting
b
Slowly detach hydro-chuck g from nipple h .

at this time.
g
Note:
hose.
h
Fig. 26
189
Step 3
Air bleeding of arm and bucket cylinder
Roll out
Retract
Extend
Roll in
CAUTION:
Make sure that nobody other than the operator is in or

hydraulic system.
Fig. 27
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
190
3 Bleeding locations
CAUTION:
4 1 Set the front-end attachment on the ground as illustrated below.
2 Stop the engine.
CAUTION:
1) Remove the rubber cap. Arm cyl.

2) Loosen the plug.
3) A mixture of air and hydraulic air will escape Arm cyl.
from the bleeder.
Bucket cyl.
6) Replace the rubber cap.
Bucket cyl.
Fig. 28
Detail L
Fig. 29
Detail M

level is low, refill the tank. Level check
Fig. 30
191
192
9-4 Mounting of bucket
Step 1
c
Mounting of bucket
a
b
1 1 Position bucket R .
2 Clean the parts a , b , c and d indicated by
.
3 Apply grease to the parts a , b , c and d d
indicated by .
R
Fig. 1
Detail A
Lift
Detail B
Shackle
Wire rope
22 mmø × Wire rope
10 000 mm 22 mmø ×
10 000 mm
R
Fig. 3
2 1 Put on the bucket, and attach wire ropes and

shackles to the bucket.
2 Lift the bucket as illustrated in Figs. 2 and 3.
Note: Fig. 2
Level the bucket by adjusting the preset chain
blocks. Lift
CAUTION: Arm

bucket.
Bucket R weight:
150°~160°
5.20 m3 : 4 910 kg (10 800 lb)
6.70 m3 : 6 650 kg (14 630 lb)
Wire rope: 2 pcs.

2 000 mm
22 mmø ×10 000 mm (L) (78 in)
(0.85 inø) (390 in L)
Shackle: 2 pcs.
Fig. 4
for 5 tonne load (5.5 US tonne load) Lift & move
3 Raise the arm top 2 000 mm (78 in) above the

ground.
4 Lift the bucket so that the pin holes a and d
indicated by become horizontal. a d
5 Move the bucket to the pin hole d indicated by

on the arm top.
Fig. 5
193
Hold
3 1 Align the centers of pin holes a and b in order to
insert the pins (both sides).
Notes:
a
i) Do not force the pins in, as doing so can cause
b
the dust seal to break.
ii) Apply grease to the pins before installation.
2 Tighten the 10 bolts, 10 spring washers. (both

sides)
C
(Bolt a ) (40 kgf·m/290 lbf·ft)
Width across flats: 30 mm Fig. 6

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

the groove and tighten their nuts.
Tightening torque:
Assemble so that no gap is provided here.
(Bolt size: M5)
Note: Slit
☆10 ~ 20 ☆10 ~ 20
Carefully seat 2 O-rings 11 on the boss arm and
bucket as shown in Figs. 8 and 8-a.
Double nut Double nut

Note:
To ease the assembly, the bolt has been made 11
slightly long. After assembly, cut the bolt to ☆10 ~ Assemble so that no
gap is provided here. Fig. 8-a
20 mm for usage.
194
4 1 Lower the bucket with a crane so that the bottom Take off wire ropes from crane.
of the bucket rests on the ground.
2 Take off wire ropes from the crane and chain
blocks lifting the bucket.
Lower
Fig. 9
5 Set the boom and arm at 120° to 140°.
120° to 140°
Fig. 10
195
6 1 Extend the bucket cylinder in the direction
of arrow to align the centers of the link
pin hole a and the bucket pin hole b , as
shown in Figs. 12 and 13.
2 Align the centers of the pin holes of the link
and bucket.
3 Grease the pins and insert.
4 To prevent the 1 pin from coming out,
secure them with 10 bolts, 10 spring
washers (see Fig. 16).

(Bolts a ) (40 kgf·m/290 lbf·ft) Fig. 11
Detail E Detail F
Bucket cylinder
(Bolts b ) (75 kgf·m/550 lbf·ft)
Note:
Apply lubricant to the bolts before tightening.
a
5 After inserting the pins, position 2 O-rings
12 in the groove and tighten their nuts.
b a
b
Tightening torque:
Assemble so that no gap is provided here.
Fig. 12 Fig. 13
Note:
Carefully seat 2 O-rings 12 on the boss arm and
bucket as shown in Figs. 14-a and 14.
Note:
To ease the assembly, the bolt has been made
slightly long. After assembly, cut the bolt to ☆10 ~
20 mm for usage.
(Bolt size: M5)
G
☆10 ~ 20 Slit ☆10 ~ 20
Fig. 14
Double nut Double nut
Detail G
12
Assemble so that no Assemble the same Bolt ~10
b parts to both sides. Spring Washer ~10
gap is provided here. Fig. 14-a
Detail H
12
Pin
Fig. 16 Fig. 15
196
Step 2 Detail I
Greasing (4)

grease gun.
automatically. a
IMPORTANT:
Note:
Bucket and Link Pins
Cap Head
Each grease fitting is provided with a protective cap.
Remove cap as shown below before greasing.
Removing/installing procedure:
Insert a screw driver into the cap cavity along the
arrow "a" direction, and scoop out the cap by
applying force in the arrow "b" direction.
When installing, push the cap by hand in the arrow
"c" direction until it bottoms or tap using screw driver Grease Cavity
Fitting
grip.
Cap Screw
Pin
Driver
Fig. 18
2 Start the engine.

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

3 Supply grease to 8 points as shown in Fig. 19.
R/H & L/H Link pin
Notes:
R/H & L/H Link pin
iii) Insufficient greasing will wear the pins. R/H & L/H Arm top pin
Fig. 19
197
d
e

Grease is sucked up and supplied to high-pressure
grease gun b .
IMPORTANT: a
pump a will be mixed in, making grease turn whitish. Fig. 20
grease. Securely close check valve cock e when all
(2) Grab high-pressure grease gun b and pay out the


g
(4) Release the lever when greasing is complete; f
grease discharge will stop. b
IMPORTANT:
taken, as follows:
pressure applied to hydro-chuck g . c Fig. 21
g

pump a , and the hose so as to ensure long life of
the components. A little grease will be discharged
at this time.
h Fig. 22
Note:
hose.
Detail K
6 Check if all the tightening bolts at the backhoe front are

securely tightened.
Fig. 23
198
Step 3 Raise
Air bleeding of cylinders
Roll out
Roll in
Lower
CAUTION: Roll out
Roll in
Make sure that nobody other than the
operator is in or on the hydraulic
excavator.
Fig. 24
hydraulic system.
procedure.
Note:
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
199
Step 4
Bleeding locations
CAUTION:
As this work is to be conducted at a height, take due safety precautions.
1 1 Set the front-end attachment on the ground in the position illustrated below (Fig. 29).
2 Stop the engine.
CAUTION:
3 Following the procedure outlined below, release the air from the cylinders, by way of the bleeding
locations indicated by .
2) Loosen the plug.
3) Air and hydraulic oil will escape together.
5) Tighten the plug securely to its original position.
6) Replace the rubber cap. Arm cyl.
Arm cyl.
Boom cyl.
Bucket cyl.
Bucket cyl.
Boom cyl.
Fig. 25
Detail L
2 Recheck the oil level in the hydraulic tank. If there is

insufficient oil, refill the tank through the oil filler port.
Position the front-end attachment as illustrated in
Level check
Fig. 26 when checking the oil level.
Fig. 26
Fig. 27
200
9-5 Adjustment of track link tension
Swing upperstructure 90° and lower bucket to raise track off

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

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

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

slowly (use long socket 24). Grease will drain from
grease outlet with valve b loosened 1 to 1.5 CAUTION!
turns. Never touch
If grease does not drain smooth, slowly rotate the
track with it raised off the ground. b Valve
Be sure to retighten valve b to 88 N·m
(9 kgf·m/65 lbf·ft) after loosening track.
Grease outlet Fig. 4
IMPORTANT:
Detail C
It is abnormal if track is still tight after turning valve b
counterclockwise or track is still loose after charging
grease to fitting a . In such cases, NEVER
DISASSEMBLE the track adjuster. See your authorized
dealer immediately.
Fig. 5
201
202
9-6 Final trial operation check
1 After connecting all the hoses, check that no hose hits Detail A
against other hose or parts.
2 1 Adjust the track link tension appropriately. (See

page 199 "Adjustment of track link tension".)
2 Check all functions of the machine. (See "Checks

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

is insufficient oil, refill the tank through the oil filler
port.
CAUTION:
Before starting, make sure there is no person other
than the operator in the hydraulic excavator.
Note:
After the above procedures 1 and 2 are Fig. 1
completed, carry out work at 60% to 70% of full
power for the first 50 operating hours, before
commencing full-power operation.
Forward Reverse
travel travel
Swing
Right
Swing
Left
Fig. 2
Forward Reverse
travel travel
Raise
Roll out
Roll in Lower
Roll in
Roll out
Fig. 3
203
1. Procedure, backhoe front (STD. Procedure) •••••••••••••••••••••••••••••••••••••• 205

2. Procedure, backhoe front (BE. Procedure) •••••••••••••••••••••••••••••••••••••• 207
3. Procedure, bucket •••••••••••••••••••••••••••••••••••••• 209
204
Detail A
1. Procedure, backhoe front (STD. Procedure)
(Front side)
5. For the covers indicated by , use those that have been used at the time of delivery
of cylinder.
(Upper structure side)
Procedure, backhoe front

Fig. 1
EX1200-6 (STD. Procedure) +++++++
205
Detail B
2. Procedure, backhoe front (BE Procedure)
Procedure, backhoe front

Fig. 2
EX1200-6 (BE Procedure) +++++++
207
Detail C
3. Procedure for bucket
Before press-insertion
Before press-insertion
(Washer, spring)
(Bolt) (Washer, spring) (Bushing)
-insertion
-insertion
(Bolt)
Before
Before
press
press
(Cover)
φ 190H8
Shaft φ 160
φ 160
Bush φ 190
Hole
Hole
(Cover)
φ 170H8
φ 140
Shaft φ 140
Bush φ 170
Hole
Hole
(Collar)
(O-ring)
(Fitting, grease)
(O-ring)
(Bushing) Press-insertion direction of bushing Press-insertion direction of bushing
(Cap)
Press-insertion direction of bushing Press-insertion direction of bushing
Outside
(Dust seal)
Assembly direction
of dust seal
(Bucket)
(Washer)
(Nameplate)
(Nut)
(Screw, drive)
(Bolt, shoe)
Tightening torque: 2600 N・m
(Cutter, side)
(Cutter, side)
NOTE
1. Make sure that the bushing is press-inserted in the right direction.
(Point, tooth) 2. The imprinting on the nameplate is as follows:
Model: EX1200-6
(Pin, lock) Front No.:
Capacity: 5.2m3
Procedure
Fig. 3
EX1200-6 for bucket +++++++
209
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
211
212
10. Checks after completing the assembly
1 After assembly, clean and wipe each part thoroughly

with a rag.
2 Inspect the excavator before starting the engine.
CYLINDERS AND
HYDRAULIC LINES
Check for oil leaks.
OPERATOR'S CAB
Clean.
OIL COOLER
Check fins.
RESERVOIR
PINS AND BOLTS Check coolant level.
Check for looseness or
absence.
RADIATOR
Clean fins.
HYDRAULIC TANK
Check oil level. ENGINE
Check oil level.
FINAL DRIVE
Check oil level. Fig. 1
(Both sides)
Checks after completing the assembly
1 Electrical system Detail A

Check for worn or frayed wires and loose
connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the Operation
Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after
completing assembly. Fig. 2
213
3 Check the instruments immediately after starting the Detail B
engine.
1 2 3 4 5 6
IMPORTANT: 7
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all
necessary measures.
8
CAB FEATURES
14
Std. Model
1 - Left Control Lever/Horn Switch (On Top of Lever) 9
2 - Left Travel Pedal
3 - Left Travel Lever 10
4 - Right Travel Lever 11
5 - Right Travel Pedal
6 - Right Control Lever
7 - Multi Function Monitor Panel 13
8 - Switch Panel
9 - Key Switch 12
10 - Air Conditioner Panel 20 15
11 - Radio
12 - Operator's Seat 16
13 - Cab Door Release Lever 17
14 - Pilot Control Shut-Off Lever
18
15 - Glove Compartment
16 - Fuse Box 19
17 - Cigar Lighter
18 - Switch Panel (Optional)
19 - Switch Panel (Optional)
Glove Compartment (Not Optional Equipped Machine)
Fig. 3
20 - Hot & Cool BoxOUTLINE
MONITOR PANEL
1 2 3 4 5 6 7
OUTLINE
1 - Work Mode Display 10 - Clock 8
2 - Auto-Idle Display 11 - Back Monitor Selector
9
3 - Heavy Lift Display 12 - Menu 18
4 - Lubrication Mode Display 13 - Auxiliary

5 - Ladder Display 14 - Auxiliary
6 - Preheat Display 15 - Auxiliary 10
7 - Hour Meter 16 - Auto-Lubrication Selection

8 - Auto-Lubrication Display 17 - Return to Basic Screen Key 11
9 - Fuel Gauge 18 - Coolant Temperature Gauge

17 16 15 14 13 12
Fig. 4
4 Measurement of engine revolutions
Determination
Standard
Item for new Engine speed
machine sensor
Low-speed idling 850 ± 50
Engine Auto idling 1 400 ± 100

revolutions
(rpm) High-speed idling 1 950 ± 50
Fig. 5
214
11. Checking machine performance
The figures and tolerances listed below are for new machines.
The measurements should be performed under the following
Note:
conditions:
Measure each actuator speed after sufficiently
· Engine speed: Maximum
operating the machine.
· Hydraulic oil temperature: 50° ± 5°C
· Site: Firm level ground
TRAVEL SPEED (20M TEST RUN)
1 Preparation
Fig. 1 Fig. 2
2 Measurement
Preliminary run Test run 20 m Preliminary run Machine at rest

7~9m (65.6 ft) 7~9m
(23 ~ 30 ft) (23 ~ 30 ft) Fig. 3
3 Determination
Front
Unit: sec
FORWARD
Item Standard
20 m (Low) 30.8 ± 2.0
20 m (High) 21.5 ± 1.6

REVERSE
215
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
Fig. 4 Fig. 5
1 Mark any one of the track shoes on the side

where this test is to be performed.
2 Jack up the track to be tested. (Figs. 4 and 5)
2 Measurement
1 Accelerate the engine to maximum speed.

2 Measure the time required to make three full
turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
3 Determination
Unit: sec.
Item Standard
Track link speed/

62 ± 4.0
Forward 3 rev. (Low)
speed
Track link speed/
43 ± 3.0
3 rev. (High)
Track link speed/

62 ± 4.0
Reverse 3 rev. (Low)
speed
Track link speed/
43 ± 3.0
3 rev. (High)
216
SWING SPEED FOR 3 TURNS
1 Preparation
Fig. 6 Fig. 7
2 Measurement
1 Set the swing control lever to full stroke.

2 Measure the time required for three full turns at a
constant speed.
Three full turns
Fig. 8
3 Determination
Unit: sec.
Item Standard
Swing speed/3 rev. R 34 ± 2
Swing speed/3 rev. L 34 ± 2
217
AMOUNT OF SWING COAST
1 Preparation
Fig. 9 Fig. 10
1 The arm cylinder should be fully retracted.

2 The bucket cylinder should be fully extended.
3 Place an aligning mark between the swing frame
and the track frame.
4 Swing the superstructure so that the swing frame
is at 180° to the track frame.
2 Measurement
1 Set the swing control lever to full stroke.

2 After swinging 180°, return the lever to the neutral
position.
3 Measure the amount of coast.
Amount of
coasting
Swing stop
180° swing
Fig. 11
3 Determination
Unit: mm (in)
Item Standard
Less than
Loader
Amount of 1 100 (42.9)
coast
(L/R) Less than
Backhoe
1 100 (42.9)
218
CYLINDER SPEEDS (Loader front)
1 Action
Boom cylinder
Fig. 12
Arm cylinder
Fig. 13
Dump cylinder
Bucket cylinder
Fig. 14 Fig. 15
2 Repeat the time measurement at least 3 times for each

item and record the average time.
Note:
For machines with a bucket tilt controller (an option),
be sure to turn the bucket control switch to OFF
when measuring the boom raise speed.
3 Determination
Unit: sec.
Item Loader Front
Raise 5.2 ± 0.5

Boom cylinder
Lower 4.0 ± 0.5
Retract 2.5 ± 0.5

Arm cylinder
Extend 2.9 ± 0.5
Tilt-in 3.3 ± 0.5

Bucket cylinder
Tilt-out 2.2 ± 0.5
Open 1.1 ± 0.5

Dump cylinder
Close 1.6 ± 0.5
219
CYLINDER SPEEDS (Backhoe front)
1 Action
Boom Cylinder
Fig. 16
Arm Cylinder
Fig. 17
2 Repeat the time measurement at least 3

times for each item and record the
average time.
Bucket Cylinder
Fig. 18
3 Determination
Unit: sec.
Application
Item STD Front BE Front
STD BE
Raise 4.9 ± 0.5 4.6 ± 0.5 9.0 m Boom 7.55 m Boom
Boom cylinder
Lower 3.3 ± 0.5 3.5 ± 0.5 3.6 m Arm 3.4 m BE Arm
5.2 m3 Bucket 6.7 m3 Bucket
Roll in 4.5 ± 0.5 4.4 ± 0.5
Arm cylinder
Roll out 4.0 ± 0.5 4.2 ± 0.5
Roll in 3.2 ± 0.5 3.2 ± 0.5

Bucket cylinder
Roll out 2.8 ± 0.5 2.7 ± 0.5
220
AMOUNT OF CYLINDER CREEP
1 Preparation
1 200 mm
(47 in)
Fig. 19
2 300 mm
(90 in)
With a full load in the bucket, set the front-end Fig. 20

attachment as shown above.
2 Measurement
Mark Mark
1 Stop the engine.
2 Measure the amount of creep over 5 minutes.
3 Determination
Fig. 21
Unit: mm (in)

A−B = Creep

Boom cylinder, mm/5min Less than 20 (0.78) Less than 20 (0.78) 30 (1.18)
Arm cylinder, mm/5min Less than 20 (0.78) Less than 20 (0.78) 30 (1.18)
Bucket cylinder, mm/5min Less than 30 (1.18) Less than 30 (1.18) 30 (1.18)
Application
STD BE
9.0 m Boom 7.55 m Boom
3.6 m Arm 3.4 m BE Arm
5.2 m3 Bucket 6.7 m3 Bucket Mark
Mark
＊ Apply touch-up paint if necessary.
Fig. 22
221
ADJUSTMENT OF CLEARANCE AT FRONT JOINT
This pages explains how to adjust the clearance at the front
joint. With too large clearance, abnormal noise is produced
when swinging the superstructure. Adjust the clearance by
using shims according to this pages.
1 Outline of Shim Adjustment
Shims at shipment
Applicable Total clearance Requirements for

Points to adjust Part No. Part Name QTY
front No. at shipment inserting a shim
BH 4309865 Shim (2.3) 3 Machine S/No. 1 mm to 9 mm Put the shim outside,

Standard ø162 x ø350 1001 and up when total clearance
boom is more than 2.5 mm.
Frame
and
BH 3 Machine S/No. 1 mm to 9 mm
boom
BE boom 1001 and up
LD 3 Machine S/No. 1 mm to 9 mm
Linkage 1001 and up
BH Not 0.5 mm to 2 mm Because the total

Standard required clearance is adjusted
arm to 2 mm and less, new
ones require no shim.
BH 0.5 mm to 2 mm
BE arm
Boom
and BH 0.5 mm to 2 mm
arm Long arm
LD 4320746 Shim (2.3) 2 mm to 10 mm Put the shim outside,

Linkage ø162 x ø340 when total clearance
is more than 2.5 mm.
Required ma x 4
shims
BH Not required 0.7 mm to 2.4 mm Becouse the total

Standard clearances
boom is adjusted to 2.4 mm
(with lock and less, new ones
bucket) require no shim.
BE 0.7 mm to 2.4 mm
Arm BE arm
and
bucket
LD 4345637 Shim (2.3) 2 Bucket 2 mm to 10 mm For total clearances of

Linkage ø142 x ø260 No. 101 more than 2 mm, put
and up the shim outside.
4245638 Shim (1.6) 2
ø142 x ø260
Frame and Put the shim outside

Shim (2.3)
Boom 4309865 3x2 4 mm to 12 mm when total clearance
ø162 x ø350
cylinder is more than 4 mm
· The shims shall be inserted in such a way that the difference in the quantity of
left and right shims can be minimized.
222
2 Points to be Inserted
Loader front
Backhoe front
Frame Inside Outside
and
Boom
Boom
Fig. 1
Arm
Loader front
Arm Inside Outside
and
Bucket
Bucket
Fig. 2
Loader front L/D Arm
Boom Inside Outside
and
Arm
Boom
Fig. 3
Backhoe front
Frame Inside Outside
and
Boom cylinder
Boom cylinder
Fig. 4
223
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku,
Tokyo 112-0004 Japan
Telephone: Tokyo (03) 3830-8050
Facsimile: Tokyo (03) 3830-8202
Printed in Japan KG

Manual de Ensamble 1200-6

Uploaded by

Copyright:

Available Formats

Manual de Ensamble 1200-6

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Ensamble 1200-6

Uploaded by

Copyright:

Available Formats

KO-356-00

Arm cylinder Level cylinder Boom cylinder

Fuel tank Oil cooler

Arm Arm cylinder

Cab Swing drive

Fuel tank Oil cooler

Front idler Counterweight

Lower roller Pump

1 RECOGNIZE SAFETY INFORMATION

Follow recommended precautions and safe operating

2 UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous situation

WARNING indicates a potentially hazardous situation

CAUTION indicates a potentially hazardous situation

The NOTE describes cautionary remarks, reference,

To avoid confusing machine protection with personal

Safety signs should be installed, maintained, and

Learn how to operate the machine and its controls

Keep your machine in proper working condition.

The safety messages in this chapter are intended to

4 DESIGNATE ONE LEADER AND TWO

5 CLEAN THE MACHINE REGULARLY

Do not spray water or steam inside the cab.

Wear close fitting clothing and safety equipment

You may need:

7 PREPARE FOR EMERGENCIES

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

8 PREPARE SUITABLE LIFTING TOOLS

10 SUPPORT RAISED BUCKET

Falling is one of the major causes of personal injury.

Never jump on or off the machine. Never mount or

13 PREVENT BATTERY EXPLOSIONS

Never check the battery charge by placing a metal

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

Disconnect the negative ground cable before working

• Avoid this hazard by relieving pressure before

• Search for leaks with a piece of cardboard, taking

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

15 CHECK EQUIPMENT SAFETY

Wear a suitable hearing protective device such as

17 FASTEN YOUR SEAT BELT

Be sure to remain seated with seat belt securely

18 BEWARE OF EXHAUST FUMES

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

Never lubricate or service the machine while it is

Before servicing the machine.

• Park the machine on a level surface.

If a maintenance procedure must be performed with the

If the machine must be raised, maintain a 90 to 110˚

Disconnect the battery ground cable (-) before making

Before performing any work on the machine, attach a

21 REMOVE PAINT BEFORE WELDING OR

Avoid potentially toxic fumes and dust.

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

Remove paint before welding or heating:

1 If you sand or grind paint, avoid breathing the

2 If you use solvent or paint stripper, remove

22 PROTECT AGAINST FLYING DEBRIS

In order to avoid personal injury, keep bystanders away