Hitachi EX1900-5 Operator's Manual
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Hitachi EX1900-5, SAFETY S-2 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 re- placed when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when order- ing). • Learn how to operate the machine and its controls cor- rectly and safely. • Allow only trained, qualified, authorized personnel to op- erate the machine. • Keep your machine in proper working condition. • U
Hitachi EX1900-5, OPERATING THE MACHINE 5-3 CONTROL LEVER (HITACHI PATTERN LOADING SHOVEL) CAUTION: Never place any part of body beyond window frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. If window is missing or bro- ken, replace immediately. Prevent possible injury from unexpected machine movement. Make sure you know the location and function of each control before operating. The machine is equipped with a label showing the control patterns of the levers and pedals. IMPORTANT: When digging, avoid hitting tracks with boom cylinders. When digging over the end of the track
Hitachi EX1900-5, OPERATOR’S STATION 1-30 WORK LIGHT SWITCH Press work light switch (1) to turn on all work lights (2). In addition, illumination for air cond. panels (3), fuel gauge (4), hydraulic oil temperature gauge (5), coolant temperature gauge (6), tachometer (7), and radio (8) will be lit. NOTE: Work light (2) will stay ON for approx. 1 minute and go OFF after the key switch is turned OFF with work light switch (1) ON. M18C-01-022 M18C-01-014 M18C-01-006 M146-01-039 1 3 6 5 4 8 7 2 2 2 2 2
Hitachi EX1900-5, OPERATOR’S STATION 1-23 DEHUMIDIFYING AND HEATING (To prevent the windshield from clouding) Set the temperature to the highest setting using tempera- ture control switch (10). (Repeatedly press temperature control switch (10) until all temperature indicators (11) turn on.) Press blower control switch (12) to turn on the blower fan. Press air conditioner switch (8). (Air conditioner indica- tor (9) should turn on.) Warm air will flow from the vents. Adjust front air flow vents (1) and side air flow vents (2) so that the air flow is directed toward the windshield. Use temperature control switch (10) and bl
Hitachi EX1900-5, OPERATOR’S STATION 1-38 HOUR METER 1- Hour Meter The right hand number indicates tenths (six minutes) of an hour. HORN SWITCH Horn switch (2) is provided on the top of the left control lever. The horn continuously sounds as long as switch (2) is pressed. CAUTION: If horn (3) does not sound when pushed, immediately stop the engine and contact your authorized dealer for repair. Operating the machine with a malfunctioning horn may result in personal injury or death. M144-01-033 M177-01-057 M146-01-010 M18C-01-014 1 3 2
Hitachi EX1900-5, MAINTENANCE 7-75 CAUTION: Use reduced compressed air pressure. (Less than 0.2 MPa, 2 kgf/cm 2 ). Clear area of bystanders, guard against flying chips, and wear personal protection equip- ment including goggles or safety glasses. 10. Clean outer element (4) using compressed air. Direct the air to the inside of the filter element, blowing out. 11. Clean the filter interior before installing outer element (4). 12. Install outer element (4) into the body to hold it in place, tighten wing nut (3) by hand. After wing nut (3)
Hitachi EX1900-5, MAINTENANCE 7-85 Clean Condenser Core --- every 500 hours CAUTION: Always wear safety glasses or gog- gles when using compressed air (Less than 0.2 MPa, 2 kgf/cm 2 , 28 psi) to clean condenser core. Remove condenser cover (2) (three pieces), located in room (1) under the cab. Use compressed air (Less than 0.2 MPa, 2 kgf/cm 2 , 28 psi) to clean the condenser core (three pieces). M18C-01-012 M146-07-010 1 2
Hitachi EX1900-5, MAINTENANCE 7-84 Check Compressor Belt Tension --- every 250 hours Remove box-type cover (2), located on step (1) under the ladder, to gain access to the compressor belt (3). Visually check belt for wear. Replace if necessary. Start the engine and run for 10 minutes. Check belt tension by depressing the midpoint between the hydraulic motor and compressor pulleys with the thumb. Deflection must be 13 to 14 mm (0.5 to 0.6 in) at a depressing force of approximately 98 N (10 kgf, 22 lbf). If tension is not within specifications, loosen the com- pressor mounting bolts to adjust belt tension. M18C-01-012 M141-07-028 M141-07-029
MAINTENANCE 7-51 Change Hydraulic Oil --- every 4000 hours, 2500 hours or 2000 hours IMPORTANT: Hydraulic oil changing intervals differ according to kind of hydraulic oils used. (See Recommended Oil Chart in this group) CAUTION: Hydraulic oil may be hot. Wait for oil to cool before starting work. 1. Park the machine on a level surface with the upper-
OPERATOR’S STATION 1-26 INDICATOR LIGHT CHECK SWITCH 1. Turn key switch to the ON position. • Alternator indicator (2), pump transmission oil pres- sure indicator (3),engine oil pressure indicator (4), en- gine stop indicator (5), and engine warning indicator (6) will come ON. If either indicator fails to light, the in- dicator bulb may be burned out. Engine
Hitachi EX1900-5, MAINTENANCE 7-31 OPERATING THE LUBRICATOR The machine is equipped with hose reel and the lubrica- tor, including the grease pump. This device is used for adding grease to the grouped fittings on the main frame and front attachment. Greasing IMPORTANT: Run the engine at medium or higher speed whenever the lubricator is used. 1. Connect hose (1) to coupler (2). 2. Move auto-lubrication toggle switch (3) located inside battery compartment to the MANUAL position. 3. Hold high-pressure grease gun (4) attached to the hose end and pull out the hose from reel (5). 4. Stop pulling hose at any desired position; reel (5
Hitachi EX1900-5, MAINTENANCE 7-9 CONSTRUCTION OUTLINE Loading Shovel Front Attachment M18C-01-040 Backhoe Front Attachment M18C-01-039 Engine Counterweight Air Cleaner Oil Cooler Intercooler·Radiator Lower Roller Pump High Pressure Strainer Front Idler Emergency Escape Device Hanger Compressor Track Adjuster Accumulator Accumulator Swing Bearing Upper Roller Boom Cylinder Bucket Cylinder Center Joint Hydraulic Oil Tank Control Valve Side Frame Travel Device Battery Swing Device Fuel Tank Ladder Lubricator Arm Cylinder Arm Bucket Boom Cab Arm Cylinder Dump Cylinder Bucket Cylinder Boom Bucket Link A Link B Arm Boom Cylinder Level Cylinder
Hitachi EX1900-5, MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9-1 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or Snowy Weather Before Operation: Check the tightness of plugs and all drain cocks. After Operation: Clean the machine and check for cracks, damaged, loose or missing bolts and nuts. Lubricate all necessary parts without delay. Near the Ocean Before Operation: Check the tightness of plugs and all drain cocks. After Operation: Thoroughly clean the machine with f
Hitachi EX1900-5, SAFETY S-10 DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direc- tion you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don’t allow personnel to stay around the machine while traveling. • Driving on a slope may cause the machine to slip or over- turn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket fa
Hitachi EX1900-5, MAINTENANCE 7-69 Drain Fuel Tank Sump --- daily 1. Park the machine on a level surface with the upper- structure rotated 90° for easier access. 2. Lower the bucket to the ground. 3. Turn the auto-idle off. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. 4. Run the engine at slow idle speed without load for five minutes. 5. Turn the key switch OFF. Remove the key from the key switch. 6. Pull the pilot control shut-off lever to the LOCK posi- tion. 7. Remove the drain plugs (2). 8. Open drain cock (1) for severa
TROUBLESHOOTING 11-8 ELECTRICAL SYSTEM Problem Cause Solution Engine Cranks Slowly Battery discharged or will not hold a charge Replace battery. Starter “dragging” See your authorized dealer. Low battery voltage Recharge or replace battery. Start relay stuck See your authorized dealer. Starter Motor Continues to Run After Engine Starts Starter solenoid stuck See your authorized dealer.
Hitachi EX1900-5, MAINTENANCE 7-80 Clean Outside of Radiator --- twice a year (in spring and autumn) Clean the outside of the radiator with radiator cleaner to remove built up rust and scale to extend the radiator life. Clean Radiator Core --- every 500 hours Clean Intercooler Core --- every 500 hours CAUTION: Always wear safety glasses or gog- gles when using compressed air (Less than 0.2 MPa, 2 kgf/cm 2 , 28 psi) to clean radiator core. IMPORTANT: Compressed air or water can damage fins. When cleaning the radiator core with compressed air or water, keep the nozzle 500 mm (20 in) or more
Hitachi EX1900-5, OPERATING THE ENGINE 3-9 Disconnecting the booster batteries 1. Disconnect black negative (–) cable from machine frame (4) first. 2. Disconnect the other end of black negative (–) cable from booster batteries (3). 3. Disconnect red positive (+) cable from booster batter- ies (2). 4. Disconnect red positive (+) cable from machine bat- teries (1). M117-03-002 Machine Batteries Booster Batteries To Upperstructure of the Machine (Red) Upper Lower (Black) Connecting the Booster Batteries 4 3 2 1
Hitachi EX1900-5, MAINTENANCE 7-124 29. Front pin-retaining bolt. (Loader) Tool: 30 mm Torque: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) Tool: 24 mm Torque: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) Tool: 36 mm Torque: 690 N⋅m (70 kgf⋅m, 510 lbf⋅ft) 30. Front pin-retaining bolt. (Backehoe) Tool: 30 mm Torque: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft) Tool: 24 mm Torque: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft) M144-07-004 M144-07-067 M144-07-066 M117-07-170
Hitachi EX1900-5, OPERATING THE ENGINE 3-7 CHECK INSTRUMENTS AFTER STARTING IMPORTANT: If indicator lights do not go out after starting engine, IMMEDIATELY STOP THE ENGINE and correct the cause. Check that 1. Hydraulic oil temperature gauge (1) is in the green or white zone. 2. Coolant temperature gauge (2) is in the green or white zone. 3. Alternator indicator (3) is off. 4. Pump transmission oil pressure indicator (4) is off. 5. Engine oil pressure indicator (5) is off. 6. Engine stop indicator (6) is off. 7. Engine noise and exhaust gas are normal. NOTE: Handy engine troubleshoo
Hitachi EX1900-5, TROUBLESHOOTING 11-10 CONTROL LEVERS Problem Cause Solution Moves Hard Corroded joint See your authorized dealer. Worn out pusher See your authorized dealer. Does Nothing Worn out pusher See your authorized dealer. Pilot valve See your authorized dealer. Does Not Return to Neutral Pilot valve See your authorized dealer. Too Much Play Worn out pivot joint See your authorized dealer. Lever is Not Vertical In Neutral Pilot valve See your authorized dealer. HYDRAULIC SYSTEM Problem Cause Solution Hydraulic Functions are Slow Low oil level Fill reservoir to full mark. Cold oil Warm up hydraulic oil to normal cycle times. Wrong oil Dr
Hitachi EX1900-5, SAFETY S-12 AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BY- STANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING
Hitachi EX1900-5, MAINTENANCE 7-17 MAINTENANCE INTERVAL GUIDE A. GREASING (See Page 7-21) Interval (hours) Parts Quantity 5 10 250 500 1000 1500 2000 Bucket Pins 8 ✱ 1. Loader Front Joint Pins Other Front Pins 11 ✱ Bucket and Link Pins 22 ✱ 2. Backhoe Front Joint Pins Other Front Pins 14 ✱ 3. Swing Bearing 4 ✱ 4. Swing Internal Gear 180 L (47.6 US gal) 5. Center Joint 1 ✱ NOTE: Maintenance required when operating in water or mud. ✱ Auto-lubrication is available. B. ENGINE (See Page 7-33) Interval (hours) Parts Quantity 10 50 250 500 1000 1500 2000 4000 - 6000 1. Engine Oil Check Oil Level 1 2. Engine Oil Change 172 L (45.4 US gal) 3. Repl
TROUBLESHOOTING 11-1 ENGINE TROUBLESHOOTING Engine troubleshooting switch (2) is located inside left con- sole side cover (1) in the cab. If any trouble occurs in the engine and/or the engine related parts, and either engine warning indicator (4) or engine stop indicator (3) illuminates or flashes continuously, the fault codes (indicating an en- gine problem by flashing the engine warning indic
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