This Article Introduces the Precautions For the Use of Doosan Excavator DX300LC Battery

 

                WARNING!

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Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.

If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or poison prevention center immediately.

When working with batteries, always wear safety glasses or goggles.

Battery generates hydrogen gas, so there is danger of an explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.

Before working with batteries, shut down engine and turn the starter switch to the "O" (OFF) position.

Avoid short circuiting the battery terminals through accidental contact with metallic objects, such as tool.

When removing or installing, check which is the positive (+) terminal and negative (-) terminal.

When removing the battery, first disconnect the negative (-) terminal. When installing the battery, first connect the positive (+) terminal.

If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion. When installing the terminals, install them tightly.

 

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Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries when they are used for the preheat cycle and when starting a cold engine. Battery performance decreases as the temperature gets lower.

In extremely cold weather, remove the batteries at night and move them to a warm location. This will help to keep them at a higher power level.

                                                     

Inspection of Battery Electrolyte Level
This machine has two maintenance free batteries. They never require the addition to water.
When the charge indicator becomes transparency, it means low electrolyte state because of the leakage or charging system error. Determine the cause of problem and replace the batteries immediately.

Check Charging State

Check charging state through the charging indicator.

• GREEN: Sufficiently charged.

• BLACK: Insufficient charged.

• TRANSPARENT: Replace battery.

 

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Check the Battery Terminals

Be certain that the battery is held securely in its compartment. Clean the battery terminals and the battery cable connectors. A solution of baking soda and water will neutralize acid on the battery surface, terminals, and cable connectors. Petroleum jelly or grease can be applied to the connectors to help prevent corrosion.

 

 

Battery Replacement

When the charging indicator indicates transparency state, replace the battery. The batteries should always be replaced in pairs.

Using an old battery with a new one will shorten the life span of the new battery.

Disassembly and inspection method of main components of Hitachi excavator diesel engine --- cylinder head cover

Disassembly and inspection of main part of Hitachi excavator ZX200-3 excavator 4HK1 diesel engine

 cylinder head cover (1) Structure (1) The cylinder head cover assembly of 4HK1 diesel engine is shown in Figure 3-3-1. 

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   (2) The cylinder head cover assembly of 6HK1 diesel engine is shown in Figure 3-3-2. 

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 (2) Disassembly

  (1) Remove the cylinder head cover. See Figure 3-3-3 for the cylinder head cover of 4HK1 diesel engine, and Figure 3-3-4 for the cylinder head cover of 6HK1 diesel engine. 

 

  

 

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 (2) Remove the gasket.

  (3) Remove the injector harness connector. 

 (4) Remove the cylinder head cover. See Figure 3-3-5 for the cylinder head cover of 4HK1 diesel engine and Figure 3-3-6 for the cylinder head cover of 6HK1 diesel engine  

 

 

  

 (5) Remove the gasket. 

       (3) Installation 

 (1) Install the gasket on the lower cover. 

 (2) Install the cylinder head cover, tighten the cylinder head cover, tightening torque: 18N m (4HK1 diesel engine), 13N m (6HK1 diesel engine).  

(3) Install the fuel injector harness connector, and insert it completely until the lock claw is lifted. 

 (4) Install the gasket to the cylinder head cover. 

 (5) Install the cylinder head cover, see Figure 3-3-7 for the installation of the cylinder head cover for the 4HK1 diesel engine, and 3-3-8 for the installation of the cylinder head cover for the 6HK1 diesel engine. Tighten the bolts in the order shown in the figure, tightening torque: 18N.m (4HK1 diesel engine), 13N.m (6HK1 diesel engine). 

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Introduction to the Structural Features of SAA6D125E-3 and SAA6D107E-1 Diesel Engines for Komatsu Excavators (PC400-7 and PC200-8)

 (1) Overall structure diagram The structure of SAA6D125E-3 diesel engine is shown in Figure 2-3-1, and the structure of SAA6D107E-1 diesel engine is shown in Figure 2-3-2.

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    (1) SAA6D125E-3 diesel engine complies with strict emission regulations: US EPA standard (2001 regulation), European regulation 2002, Japanese construction equipment regulation 2003, it is a diesel engine with high performance, high efficiency, low fuel consumption and low noise, Improved exhaust color, improved acceleration. 

 (2) SAA6D125E-3 diesel engine and SAA6D107E-1 diesel engine are both in-line, 6-cylinder, water-cooled, direct-injection diesel engines. 

 (3) SAA6D125E-3 diesel engine and SAA6D107E-1 diesel engine adopt electronically controlled common rail fuel injection system, which injects high-pressure fuel at a pressure of 118MPa, which can provide the best injection control to match the speed and load, thereby improving Diesel engine emission performance, reducing fuel consumption and noise. 

 (4) The piston is made of high-quality steel, cast in a vibratory cooling furnace, and has the lowest thermal expansion in Komatsu tradition, which improves the reliability and life of the diesel engine. 

 (5) SAA6D125E-3 diesel engine and SAA6D107E-1 diesel engine adopt electronically controlled common rail fuel injection system and the design of optimal divergence characteristics at low temperature startup, which improves startup performance and reduces white smoke emission. 

 (6) The turbocharger used on the 125E-2 diesel engine is improved, so that the air supply cycle part can control the impact at the end of the compressor, so that the performance is optimal, the speed range from low speed to high speed is wider, and the fuel consumption is lower .

  (7) The thickness of the top surface of the cylinder block is increased, which can prevent deformation after long-term operation and make remanufacturing easier. In addition, by increasing the rigidity of the main reinforcement, the rigidity of the main body is improved, the deformation and vibration under load are reduced, and the generation of various noises is prevented. 

 (8) The size of the fuel supply pump of the electronically controlled common rail fuel injection system is 1/3 of the fuel supply pump of the ordinary in-line fuel injection system. In addition, the flange is used instead of the mounting seat, and it is tightly connected with the timing gearbox, thereby reducing noise.

  (9) The air filter is changed from ordinary end face seal to radial seal to prevent dust from entering and damaging parts. Additionally, a 5-segment display-type air filter clogging sensor provides accurate information on cleaning times.  

(10) The oil filter is a filter that combines high performance and high efficiency.

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(11) The fuel filter is a special fuel filter with high performance and high efficiency, which can filter out small particles of dirt and protect the electronically controlled common rail fuel injection system. 

 (12) If the electronic control unit judges that the diesel engine is working abnormally, it will issue a warning and the system will switch to the emergency escape mode. 

 (13) After starting the diesel engine at a very low temperature, if the diesel engine speed suddenly increases, the overload will apply excessive load to the bearing before the lubrication is sufficient, which will reduce the service life of the diesel engine, especially the overload will damage Non-locating bearings for turbochargers. In order to prevent this situation, a turbo protection system is installed to limit the diesel engine speed.