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Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual – PDF Download
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Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual
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Description
Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual
FILE DETAILS:
Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual
LANGUAGE:ENGLISH
PAGES:984
DOWNLOADABLE:YES
FILE TYPE:PDF
HITACHI EX120 EXCAVATOR WITH ISUZU ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T ENGINES SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual
This service manual is for training new personnel and for reference by experienced service techni— clan. lt works to give you both the general background as a training text and technical details of shop service and field service. It is concise service guide for specific machine. lt covers specifications construction, theory of operation, trouble shooting, removal and installation, disassembly and assembly, maintenance and repair. Using the service manual as a guide will reduce error and costly delay. It will also assure you the best in finished service work.
TABLE OF CONTENTS:
Hitachi EX120 Excavator With Isuzu ZU 4BD1 4BD1T 6BB1 6BD1 6BD1T Engines Service Repair Manual
EX120 HYDRAULIC EXCAVATOR SERVICE MANUAL .................................................................... 0 SECTION 01 HOW TO USE.................................................................................... 1 Group 01 Section & Group Contents.................................................................... 2 Group 02 Introduction................................................................................ 5 Introduction .................................................................................... 5 Care of the Handling............................................................................. 5 Symbols.......................................................................................... 6 Group 03 Features of This Manual..................................................................... 7 Construction..................................................................................... 7 Tab ............................................................................................. 8 Page............................................................................................. 8 Contents......................................................................................... 8 Group 04 Safty Informations ......................................................................... 9 SECTION 02 SPECIFICATIONS................................................................................ 12 Group 01 General Specifications...................................................................... 14 Dimensions....................................................................................... 14 Weights and Ground Pressure...................................................................... 15 Capability....................................................................................... 15 Backhoe Attachments.............................................................................. 15 Other Attachments................................................................................ 15 Working Ranges................................................................................... 16 Lifting Capacities............................................................................... 17 Group 02 Components Specifications................................................................... 18 Engine........................................................................................... 18 Main Pump........................................................................................ 22 Pilot Pump ...................................................................................... 23 Control Valve.................................................................................... 24 Swing Motor...................................................................................... 24 Travel Motor .................................................................................... 25 Center Joint..................................................................................... 25 Pilot Valve (for Travel)......................................................................... 26 Pilot Valve (for Swing,Boom,Arm,Bucket).......................................................... 26 Control Neutralizer Valve........................................................................ 26 Shockless Valve.................................................................................. 26 Accumulator...................................................................................... 26 Hydraulic Tank................................................................................... 26 Suction Filter................................................................................... 27 Full-Flow Filter................................................................................. 27 Air Breezer...................................................................................... 27 Bypass Check Valve............................................................................... 27 Pilot Filter..................................................................................... 27 Oil Cooler....................................................................................... 27 Restriction Valve................................................................................ 27 Solenoid Valve................................................................................... 28 Mode Selection Cylinder.......................................................................... 28 Boom Cylinder.................................................................................... 28 Arm Cylinder..................................................................................... 28 Bucket Cylinder.................................................................................. 28 Group 03 Torque Reference............................................................................ 29 Group 04 Others...................................................................................... 34 maintenance Intervals............................................................................ 34 Group 05 Conversion Table............................................................................ 36 SECTION 03 GENERAL....................................................................................... 42 Group 01 Introduction................................................................................ 43 Group 02 Construction................................................................................ 44 Group 03 Hydraulic System............................................................................ 47 Hydraulic System................................................................................. 47 Main Hydraulic Circuit........................................................................... 48 Pilot Hydraulic Circuit.......................................................................... 52 Group 04 Electric System............................................................................. 56 Main Circuit..................................................................................... 56 Control System................................................................................... 57 Monitor System................................................................................... 57 Group 05 Maintenance................................................................................. 58 Removal and Instrallation........................................................................ 58 Maintenance...................................................................................... 71 Name Plate....................................................................................... 83 SECTION 04 SUPERSTRUCTURE................................................................................ 86 Group 01 Superstructure.............................................................................. 88 Main Frame and Counter-Weight.................................................................... 88 Engine........................................................................................... 90 Hydraulic Oil Tank...............................................................................102 Fuel Tank........................................................................................106 Swing Device.....................................................................................108 Electric Parts...................................................................................113 Cab Heater.......................................................................................117 Engine Control Lever.............................................................................119 Main Piping .....................................................................................120 Oil Cooler Piping................................................................................122 Cover............................................................................................127 Main Pump........................................................................................130 Control Box......................................................................................136 Cab Group........................................................................................144 Pilot Piping.....................................................................................151 Control Lever....................................................................................158 Group 02 Hydraulic Pump Device.......................................................................162 O/P, Hydraulic Pump..............................................................................162 Outline......................................................................................162 Function.....................................................................................164 Operation....................................................................................169 D/A, Main Pump ..................................................................................179 Disassembly..................................................................................179 Assembly.....................................................................................191 Parts List...................................................................................203 Group 03 Control Valve...............................................................................207 O/P, CV-22M Control Valve........................................................................207 General......................................................................................207 Construction and Function....................................................................211 D/A, CV-22M Control Valve........................................................................228 Disassembly..................................................................................228 Inspection ..................................................................................239 Assembly.....................................................................................240 Group 04 Swing Device................................................................................263 O/P, Swing Motor ................................................................................263 Outline......................................................................................263 Function.....................................................................................266 D/A, Swing Motor ................................................................................276 Disassembly..................................................................................276 Inspection...................................................................................285 Assembly.....................................................................................287 Special Tools................................................................................299 D/A, Swing Reduction Device......................................................................305 Disassembly..................................................................................305 Assembly.....................................................................................309 Group 05 Pilot Valve.................................................................................315 O/P, Pilot Valve.................................................................................315 Outline......................................................................................315 Function.....................................................................................317 D/A, HV Type Pilot Valve (Front-End Attachment) .................................................322 Disassembly..................................................................................322 Assembly.....................................................................................328 D/A, HV Type Pilot Valve (Travel)................................................................336 Disassembly..................................................................................336 Assembly.....................................................................................342 Group 06 Control Neutralizer Valve...................................................................350 O/P, Control Neutralizer Valve ..................................................................350 Outline......................................................................................350 Function.....................................................................................351 D/A, Control Neutralizer Valve...................................................................352 Disassembly..................................................................................352 Assembly.....................................................................................354 Group 07 Shockless Valve.............................................................................357 O/P, Shockless Valve.............................................................................357 Outline......................................................................................357 Function.....................................................................................358 D/A, Shockless Valve.............................................................................362 Disassembly..................................................................................362 Inspection...................................................................................365 Assembly.....................................................................................366 Group 08 Accumulator.................................................................................371 O/P, Accumulator.................................................................................371 Outline......................................................................................371 Function.....................................................................................372 Group 09 Solenoid Valve..............................................................................373 O/P, Solenoid Valve.............................................................................373 Outline......................................................................................373 Function.....................................................................................374 D/A, Solenoid Valve.............................................................................378 Disassembly..................................................................................378 Inspection...................................................................................382 Assembly.....................................................................................383 Group 10 Mode Selection Cylinder.....................................................................388 D/A, Mode Selection Cylinder.....................................................................388 Disassembly..................................................................................388 Assembly.....................................................................................389 SECTION 05 UNDERCARRIAGE.................................................................................392 Group 01 Undercarriage...............................................................................393 Track Frame......................................................................................393 Swing Bearing ...................................................................................395 Travrl Device and Piping.........................................................................402 Front Idler.....................................................................................412 Adjuster.........................................................................................419 Upper Roller and Lower Roller....................................................................431 Track Link.......................................................................................445 Center Joint.....................................................................................455 Group 02 Travel Devece...............................................................................462 O/P, Travel Motor................................................................................462 Outline......................................................................................462 Travel Motor.................................................................................462 Brake Valve Assembly.........................................................................466 D/A, Travel Motor................................................................................469 Disassemble Travel Motor.....................................................................469 Inspect Travel Motor.........................................................................477 Assemble Travel Motor........................................................................479 Special Tools................................................................................491 Disassemble Brake Valve......................................................................494 Assemble Brake Valve.........................................................................499 Special Tools................................................................................507 D/A, Travel Divice...............................................................................510 Dissembly....................................................................................510 Assembly.....................................................................................517 Special Tools................................................................................528 Group 03 Center Joint................................................................................533 O/P, Center Joint................................................................................533 Outline......................................................................................533 D/A, Center Joint ...............................................................................534 Disassembly..................................................................................534 Assembly.....................................................................................537 Special Tools................................................................................540 SECTION 06 FRONT-END ATTACHMENT .........................................................................542 Group 01 FRONT-END ATTACHMENT .......................................................................543 Boom Assembly....................................................................................543 Arm Assembly....................................................................................545 Bucket Assembly.................................................................................548 Front Pipings....................................................................................560 Group 02 Hydraulic Cylinder..........................................................................574 Operational Principle............................................................................574 Construction and Function....................................................................574 Disassembly and Assembly........................................................................575 Disassembly..................................................................................575 Inspection...................................................................................579 Assembly.....................................................................................580 Special Tools................................................................................584 Group 03 Pin and Bushing.............................................................................587 Specifications...................................................................................587 Group 04 Point and Side Cutter.......................................................................589 Maintenance......................................................................................589 SECTION 07 HYDRAULIC SYSTEM..............................................................................590 Group 01 Outline.....................................................................................592 Group 02 Main Hydraulic Circuit......................................................................593 Suction Circuit and Delivery Circuit.............................................................593 Return Circuit...................................................................................597 Drain Circuit....................................................................................599 Group 03 Pilot Circuit...............................................................................602 Suction,Delivery and Return Circuit..............................................................603 Accumulator......................................................................................605 Control Neutralizer Valve........................................................................605 Pump Displacement Control Circuit................................................................607 Relief pressure Change Circuit ..................................................................610 Switch Valve Circuit.............................................................................610 Heat-Run Circuit.................................................................................611 Swing Parking Brake Circuit......................................................................613 Group 04 Single Operation............................................................................615 Boom Raise Circuit Operation.....................................................................615 Boom Lower Circuit Operation ....................................................................616 Arm Roll-In Circuit Operation....................................................................617 ArmRoll-Out Circuit Operation....................................................................618 Bucket Circuit Operation.........................................................................619 Swing Circuit Operation..........................................................................620 Swing Operation..................................................................................622 Travel Circuit Operation.........................................................................623 Travel Forward and Reverse Operation.............................................................625 Group 05 Combined Operation..........................................................................627 Outline..........................................................................................627 Combined Swing and Boom Operation................................................................628 Combined Swing and Arm Operation.................................................................629 Combined Swing and Bucket Operation..............................................................630 Combined Swing, Boom, Arm and Buket Operation....................................................631 Combined Swing and Travel Operation..............................................................632 Combined Boom and Travel Operation ..............................................................633 Combined Arm and Travel Operation ...............................................................634 Combined Bucket and Travel Operation ............................................................635 Group 06 Extra Control Circuit.......................................................................636 Outline .........................................................................................636 Single Operation.................................................................................638 Combined Extra and Arm Roll-In Operation.........................................................639 Combined Extra and Arm Roll-Out Operation........................................................640 SECTION 09 ELECTRICAL SYSTEM.............................................................................642 Group 01 Safety Precautions..........................................................................643 Safety Precautions...............................................................................643 Group 02 Specifications .............................................................................644 Battery, Starter, Safety, Relay, Alternator, Regulator, Headlight, Wiper Motor, Speaker, Fuse....644 Group 03 Construction and Function...................................................................646 Construction of Electrical System................................................................646 Monitor..........................................................................................648 Control (E-P Control) System.....................................................................657 Engine Reverse Rotation Preventive Device........................................................666 Function of Seneors and Relays...................................................................668 Group 04 Circuit Operations..........................................................................674 Characteristics of Electrical Circuit............................................................674 Electrical Circuit...............................................................................675 Battery Circuit..................................................................................677 Preheat Circuit..................................................................................678 Starting Circuit.................................................................................679 Charging Circuit.................................................................................681 Safety Circuit...................................................................................685 Engine Emergency Stop Circuit....................................................................686 Accessory Circuit................................................................................691 Gauge Panel Circuit..............................................................................692 Control Circuit..................................................................................693 Group 05 Maintenance.................................................................................694 Replacing Panel Gauge Parts......................................................................694 Assembly and Adjustment of Engine Control Device.................................................702 SECTION 10 TROUBLSHOOTING ...............................................................................704 Group 01 Introduction................................................................................706 General Information..............................................................................706 Notes on Performance Measurement.................................................................708 Group 02 Diagnose Malfunctions.......................................................................711 Malfunctions Phenomena...........................................................................711 Hydraulic System.............................................................................713 Electric System..............................................................................727 Group 03 Excavator Performance Test..................................................................757 Introduction ....................................................................................757 Engine Performance Measurement...................................................................757 Travel Performance Measurment....................................................................760 Swing Performance Measurement....................................................................767 Front-end Attachment.............................................................................771 Control Lever Performance Measurement............................................................775 Group 04 Components Performance Standard.............................................................779 Introduction.....................................................................................779 Pilot Relief Valve ..............................................................................779 Main Relief Valve................................................................................781 Overlord Relief Valve............................................................................783 Swing Overload Relief Valve......................................................................785 Travel Crossover Relief Valve....................................................................786 Main Hydraulic Pump..............................................................................787 Travel Motor.....................................................................................796 Swing Motor......................................................................................797 Group 05 Electrical System Test......................................................................798 Commom Circuit Test..............................................................................798 Articles Necessary for Electric Circuit Test.....................................................800 Measurement Procedure............................................................................801 Measurement Standard.............................................................................802 SECTION 11 ENGINE .......................................................................................813 Group 01 General Instructions .......................................................................816 General Repair Instructions......................................................................816 Notes on the Format of this Manual...............................................................816 Main Data and Specifications.....................................................................820 Design Features and General Outline..............................................................824 Tightening Torque Specifications.................................................................827 Anglular Nut and Bolt Tightening Method..........................................................828 Major Parts Fixing Nut and Bolts.................................................................830 Identifications..................................................................................841 Group 02 Maintenance.................................................................................842 Lubricating System...............................................................................842 Fuel System......................................................................................843 Cooling System...................................................................................847 Valve Clearance and Adjustment...................................................................847 Injection Tinming................................................................................849 Compression Pressure Measurement.................................................................855 Turbocharger Inspection..........................................................................856 Engine Repair Kit................................................................................857 Recommended Lubricants...........................................................................859 Engine Oil Viscosity Chart.......................................................................859 Group 03 Engine Disassemble..........................................................................860 Exterminal Parts.................................................................................860 Major Components.................................................................................868 Rocker Arm and Rocker Arm Shaft..................................................................870 Cylinder Head....................................................................................871 Piston and Connecting Rod........................................................................872 Group 04 Inspection and Repair.......................................................................874 Cylinder Head....................................................................................874 Valve Guide......................................................................................875 Valve Spring.....................................................................................878 Tappet...........................................................................................879 Push Rod.........................................................................................880 Rocker Arm Shaft and Rocker Arm..................................................................881 Idler Gear and Idler Gear Shaft..................................................................881 Cam Shaft........................................................................................882 Cylinder Body and Liner..........................................................................883 Piston and Piston Ring...........................................................................888 Piston Pin.......................................................................................889 Connecting Rod...................................................................................890 Crank Shaft......................................................................................892 Fly Wheel and Fly Wheel Housing..................................................................900 Timing Gear Case Cover...........................................................................901 Group 05 Engine Assembly.............................................................................902 Piston and Connecting Rod........................................................................902 Cylinder Head....................................................................................904 Rocker Arm and Rocker Arm Shaft..................................................................908 Major Components.................................................................................909 External Parts...................................................................................919 Engine Tuning Operation..........................................................................926 Engine Section View..............................................................................928 Group 06 Lubricating System..........................................................................929 General Description..............................................................................929 Oil Pump.........................................................................................930 Main Oil Pump....................................................................................932 Oil Cooler.......................................................................................934 Group 07 Cooling System..............................................................................936 General Description..............................................................................936 Water Pump.......................................................................................937 Thermostat.......................................................................................942 Group 08 Fuel System.................................................................................943 General Description..............................................................................943 Fuel Filter......................................................................................944 Injection Nozzle.................................................................................946 Group 09 Turbocharger................................................................................951 General Description..............................................................................951 Identification...................................................................................952 Roter Shaft Play Inspection......................................................................953 Group 10 Engine Electricals..........................................................................954 Starter Motor....................................................................................954 Alternator.......................................................................................957 Group 11 Troubleshooting.............................................................................961 Head Starting....................................................................................961 Unstable Low Idling..............................................................................965 Insufficient Power...............................................................................968 Excessive Fuel Consumption.......................................................................971 Overheating......................................................................................974 White Exhaust Smoke..............................................................................976 Darkish Exhaust Smoke............................................................................977 Not Rising Oil Pressure..........................................................................978 Abnormal Engine Noise............................................................................980 Group 12 Special Tool List...........................................................................983
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⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual
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