Tata Hitachi EX 210LC Prime Maintenance Checklist
Daily pre-start checks · Service schedule by operating hours · Warning alert actions — Cummins 6BT5.9C engine, Tata Hitachi Extended Service Interval (ESI) program
Daily Pre-Start Checklist
Complete all items before every shift start. Do not start the engine without finishing all checks. The Cummins 6BT5.9C engine requires daily oil and coolant monitoring.
Engine Oil
Dipstick check — level between MIN and MAX. Top up if needed (22.0 L total). Use Cummins-approved SAE 15W-40 CJ-4/CK-4 only. Inspect sump plug and filter housing for seepage.
Act if: below MIN, milky/foamy oil (coolant mixing) or any active leak — do not start.
Engine Coolant
Overflow reservoir between LOW and FULL. Top up with 30–50% ethylene glycol mix (system: 25.0 L). Check hoses and clamps for leaks.
Do NOT open the radiator cap when the engine is hot — risk of scalding.
Hydraulic Oil
Sight glass check (machine in travel position) — level in green zone. System: 220 L, tank: 129 L. Check all hoses, cylinder rods and fittings for leaks.
Act if: below green zone or oil looks milky (water contamination) — do not operate.
Fuel Level
Check gauge — fuel tank 300 L. Drain water from the pre-filter sediment bowl. Refuel before the shift begins from a clean filtered source.
Never run dry — running out requires fuel system priming and bleeding.
Air Filter
Inspect cyclonic pre-cleaner restriction indicator. Clean pre-cleaner if in the yellow zone.
Act if: indicator in red zone — replace primary element. Never run without the filter fitted.
Battery & Electrics
Check 2×12 V battery terminals — clean corrosion if present. Verify battery cut-off switch position. Start and confirm all gauges on the 7" TFT LCD monitor power up normally.
Act if: corroded/loose terminals or any fault code on the monitor — resolve before operating.
Tracks & Undercarriage
Walk both tracks — check sag mid-span (allowable: 10–30 mm). Remove stone packing, mud and debris from track links and rollers. Inspect 48 shoes per side.
Act if: sag out of range, packing present or cracked/broken shoe bolt holes — correct before operating.
Controls & Monitoring
Test boom, arm, bucket and swing controls for smooth response. Check the rear-view camera image (if fitted). Verify InSite 4G telematics is connected and logged in.
Act if: any control sluggish/erratic or fault codes on the 7" LCD — report before operating.
Greasing
Grease all boom, arm, bucket, H-link and linkage pins with EP-2 lithium grease before starting work.
In dusty or wet conditions, grease every 4–8 operating hours instead of daily.
Cab & Safety
Seatbelt secured and alarm functional. Front guard in place. Horn, back-up beeper and all warning alarms operational. Verify FOPS cab frame integrity.
Ensure the fire extinguisher is fitted and charged. Do not operate with a damaged guard.
Service Schedule by Hourmeter
All intervals are operating (engine) hours, not calendar time. Read cumulatively — carry forward all lower-interval tasks at each higher milestone. CHANGE = fluid/filter change CHECK = inspect or verify.
Engine oil & coolant
Check levels — top up as required (oil 22.0 L | coolant 25.0 L)
Fuel level & water separator
Check gauge (300 L); drain water separator sediment bowl
Hydraulic oil
Check sight glass; inspect hoses + cylinders (system 220 L | tank 129 L)
Greasing
Grease all pins (boom, arm, bucket, H-link, linkages) — EP-2 lithium; every 4–8 h in dusty/wet
Air filter indicator
Check cyclonic pre-cleaner restriction indicator — clean if yellow, replace primary if red
Radiator & oil cooler
Clean fins — compressed air from engine side outward (max 30 psi); pressure-wash if heavily blocked
Coolant concentration
Test ethylene glycol — 30–50%; top up as needed, inspect hoses
Hoses & belts
Inspect belts, all hoses and clamps — replace if cracked, glazed, frayed or loose
Hydraulic hoses
Inspect all hoses for swelling/chafing — replace any showing external damage
Track tension
Measure track sag mid-span — adjust if out of spec (10–30 mm)
Greasing
Full lubrication of all pins — EP-2 lithium
Engine oil + filter
Change engine oil and replace oil filter — 22.0 L SAE 15W-40 CJ-4/CK-4, Cummins approved
Drive belts
Inspect alternator + drive belts; check idler pulley — replace if worn or tension lost
Primary fuel filter
Replace element; bleed fuel system afterwards — never run dry
Primary air filter
Replace element — never clean with compressed air beyond 3 times; safety element at 1000h
Hydraulic oil sample
Take oil sample for lab analysis — validates the 4500h ESI period
Rollers / idlers / sprockets
Inspect lower rollers (8/side), upper (2/side), sprockets — check seepage, wear, bearing play
Engine oil + all filters
Change engine oil; replace oil, fuel and primary air filters — 22.0 L SAE 15W-40
Air filter safety element
Replace — do NOT clean; replace regardless of restriction indicator reading
Drive & alternator belts
Replace — do not reuse beyond 1000h even if visually OK
Fault code review
Download fault history via InSite / 7" LCD; clear only after review and diagnosis
Swing device oil
Check level — total capacity 6.7 L SAE gear oil; change at 2000h
Boom, arm & frame
Inspect all welds and parent metal for cracks — boom–arm pivot, boom foot, bucket corners
Counterweight & boom bolts
Torque-check counterweight + boom-to-frame bolts per TH spec; re-torque if loose
Travel device oil — both sides
Change gearbox oil — 6.8 L SAE gear oil per side (13.6 L total); inspect sprockets and idler bearings
Swing device oil
Change — 6.7 L SAE gear oil; clean magnetic drain plug
Track link pitch
Measure for elongation — replace chain if it exceeds TH specification
Full undercarriage measurement
Measure wear — all shoes (48/side), rollers, idlers, sprockets (TH authorised technician)
Track shoe bolts
Torque-check all 48 shoes per side; replace stripped or loose bolts
Pins & bushes
Inspect and measure all boom, arm, bucket, H-link pins — replace any at wear limit per TH spec
InSite firmware
Update telematics firmware if notified by Tata Hitachi; verify 4G connectivity
Hydraulic oil — full change
Drain full system, flush tank and refill — system 220 L, tank 129 L (TH-approved oil only)
HP return line filter
Replace element — core to the 4500h ESI hydraulic interval
Case drain & pilot filters
Replace case drain filter + pilot filter if due; inspect all filter seals and housings
Hydraulic tank clean
Clean inside tank; inspect suction strainer and line; replace tank breather
Coolant — full change
Flush and replace — 25.0 L, 30–50% ethylene glycol; pressure-test radiator cap and hoses
Full engine service
Engine oil (22.0 L), oil/fuel/air filters and belts; full turbocharger and injection inspection
Extended warranty review
Review extended warranty / ASC / FMC contract status — contact nearest TH dealer to plan next period
Warning Alerts & Immediate Actions
Monitor the 7" TFT LCD monitor for fault codes and alerts. Always note the fault code number before acknowledging or clearing any alert.
Engine Oil Pressure Low
Oil pressure has dropped — metal-to-metal contact occurring inside the engine.
Immediate action: STOP immediately. Do NOT restart. Check oil level (22.0 L). If level is OK, do not restart — call Cummins / Tata Hitachi service.
Risk if ignored: running with low oil pressure destroys engine bearings.
Engine Coolant Temperature High
Coolant temperature has exceeded the safe limit. Engine at risk of thermal seizure.
Immediate action: stop work. Idle 3–5 min to cool the turbocharger, then shut off. Do NOT open the radiator cap hot. Check coolant (25.0 L), radiator fins, thermostat and water pump belt.
Risk if ignored: warped cylinder head, blown head gasket, seized engine.
Travel Alarm / Brake Fault
Travel or parking brake system fault detected.
Immediate action: stop travel immediately. Apply swing parking brake. Park on a level surface. Do NOT attempt to tram the machine. Check travel device oil level (6.8 L per side).
Risk if ignored: loss of travel/brake control — call Tata Hitachi service for diagnosis.
Cummins Engine Fault Code
Engine controller has logged a fault code on the 7" TFT LCD monitor.
Immediate action: NOTE the fault code number before clearing. RED: stop immediately and call Tata Hitachi dealer / Cummins service. AMBER: reduce load and schedule service within 8 operating hours.
Risk if ignored: undiagnosed faults escalate to major component failure.
Hydraulic Oil Temperature High
Hydraulic oil temperature is dangerously high. Seals and hoses can fail.
Immediate action: reduce load — hold the boom raised and idle 5–10 min to cool the oil. Check the hydraulic oil cooler fins for blockage and check oil level. If it persists, stop work and call service.
Risk if ignored: pump seal failure, cylinder seal damage, control valve damage.
Hydraulic Oil Level Low
Hydraulic oil is below the minimum level.
Immediate action: park on level ground. Check the sight glass. Inspect all cylinder rods and hose connections for active leaks. Top up with TH-approved oil to the green zone. Do not operate with level in the red.
Risk if ignored: pump starvation, cavitation damage, complete hydraulic failure.
Air Filter Restriction
Air filter is becoming blocked. The engine is receiving less air than required.
Immediate action: stop work at a safe position. Clean the cyclonic pre-cleaner first. If the indicator is still in the red zone after cleaning, replace the primary element. Never operate without the air filter.
Risk if ignored: power loss, black smoke, overheating, injector damage to the Cummins 6BT5.9C.
Fuel Level Low
Fuel tank approaching empty (300 L tank).
Immediate action: move to a safe refuelling location and refuel from a clean filtered source. Drain the water separator bowl after refuelling. Do NOT run the fuel dry.
Risk if ignored: running dry requires fuel system bleeding and priming before restart.
Engine Coolant Level Low
Coolant level has dropped below minimum.
Immediate action: let the engine cool completely — do NOT remove the radiator cap while hot. Check all hoses and clamps for leaks. Top up with 30–50% ethylene glycol mix (25.0 L system).
Risk if ignored: overheating and engine damage. Never add plain water alone.
Battery / Charging Fault
Alternator is not charging the battery correctly.
Immediate action: check 2×12 V battery terminals — clean if corroded. Inspect the alternator drive belt for tension and wear. Check the battery cut-off switch position. If the fault persists, stop work and call an electrician.
Risk if ignored: machine will not restart; a broken belt also causes rapid overheating.
Starter Thermal Cut-off
The starter motor has tripped its thermal protection.
Immediate action: wait 2–3 minutes before re-cranking. Do NOT crank continuously. If the engine fails to start after 3 attempts, call Tata Hitachi service.
Risk if ignored: continuous cranking damages the starter motor windings.
InSite Telematics Alert
An alert has been raised by the InSite telematics platform (app or SMS).
Immediate action: check the InSite app/SMS for the description. Service-due alerts: schedule at the nearest authorised TH dealer. Geo-fence breach: verify machine location and report to the fleet manager immediately.
Risk if ignored: missed service intervals and unmonitored asset movement.
Dig. Depth
Dump Height
