Performing suspension alignment on a Hitachi EX1200-5 Excavator is a complex process that requires a thorough understanding of the machine’s components and systems. click here for more details on the download manual…..
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Below are detailed steps and descriptions of the tools required for the alignment process.
### Tools and Equipment Needed
– **Laser Alignment Tool**
– A precision tool that uses a laser beam to measure alignment. It helps in ensuring that all axles and suspension components are aligned accurately.
– **Digital Level**
– A digital leveling tool that measures angles and slope; essential for checking the level of the machine and its components during alignment.
– **Torque Wrench**
– A tool used to apply a specific torque to fasteners, ensuring that bolts are tightened to the manufacturer’s specifications.
– **Grease Gun**
– A device for applying lubricant to suspension components, which is crucial for maintaining smooth operation and preventing wear.
– **Measuring Tape**
– A measuring tool used to measure distances between suspension components and ensure correct spacing and alignment.
– **Socket and Ratchet Set**
– A set of various-sized sockets and ratchets to remove and install bolts and nuts on suspension components.
– **Service Manual for Hitachi EX1200-5**
– A comprehensive guide that provides specifications, diagrams, and procedures specific to the Hitachi EX1200-5, ensuring adherence to manufacturer standards.
– **Safety Gear**
– Personal protective equipment (PPE) including gloves, safety glasses, and steel-toed boots to protect the technician during the alignment process.
### Suspension Alignment Process
– **Preparation**
– Ensure the excavator is parked on a flat, stable surface. Engage the parking brake to prevent movement during the alignment process.
– Put on all necessary safety gear.
– **Inspect Suspension Components**
– Thoroughly examine all suspension components, including bushings, joints, and links, for wear or damage. Replace any worn or damaged parts before proceeding with alignment.
– **Lift the Excavator**
– Use a hydraulic jack or appropriate lifting equipment to raise the excavator, allowing access to the undercarriage and suspension components. Secure with jack stands for safety.
– **Check Level and Plumb**
– utilize the digital level to ensure that the excavator is perfectly level before beginning the alignment process. Adjust as necessary.
– **Measure Suspension Geometry**
– Use the measuring tape to take baseline measurements of the suspension components. Document these measurements for comparison after adjustments are made.
– **Laser Alignment Setup**
– Set up the laser alignment tool according to the manufacturer’s instructions. Position the laser at a reference point on the excavator to project a straight line for alignment.
– **Adjust Suspension Components**
– Begin adjusting the suspension components based on the measurements taken. This may involve loosening bolts and repositioning parts to ensure they align with the laser’s reference line.
– Use the torque wrench to tighten bolts to the specified torque settings as per the service manual once adjustments are made.
– **Check Alignment**
– After adjustments, check the alignment using the laser tool
and compare with the baseline measurements. Make any necessary fine adjustments to achieve proper alignment.
– **Lubricate Components**
– Use the grease gun to apply lubricant to all moving parts of the suspension system to ensure smooth operation and reduce wear.
– **Final Inspection**
– Conduct a thorough final inspection of all suspension components, ensuring everything is secure and properly aligned.
– Recheck all torque settings to ensure they meet manufacturer specifications.
– **Lower the Excavator**
– Carefully lower the excavator back to the ground and remove any tools or equipment used during the alignment process.
– **Test Operation**
– Before putting the excavator back into regular use, conduct a test operation to ensure that the suspension system functions correctly and that the alignment has been successfully achieved.
### Documentation
– **Record All Findings**
– Document all measurements, adjustments made, and any parts replaced. This information can be valuable for future reference and maintenance.
– **Report to Maintenance Log**
– Update the maintenance log for the Hitachi EX1200-5 with details of the alignment process conducted, including dates, findings, and any parts ordered or replaced.
By following these detailed steps and using the appropriate tools, you can perform a suspension alignment on a Hitachi EX1200-5 Excavator effectively and safely. always refer to the service manual for specific details related to your machine’s model.
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