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Hitachi EX1200-5 Excavator Technical Workshop Manual – PDF Download
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Description
Hitachi EX1200-5 Excavator Technical Workshop Manual
File Details:
Hitachi EX1200-5 Excavator Technical Workshop Manual
- Manual Language:English
- Pages: 467
- Size: 7.55 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX1200-5 EXCAVATOR TECHNICAL WORKSHOP MANUAL – PDF DOWNLOAD:
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Description:
Hitachi EX1200-5 Excavator Technical Workshop Manual
TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• Operation Manual of the Engine
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.
Table Of Contents:
Hitachi EX1200-5 Excavator Technical Workshop Manual
INTRODUCTION........................................................................................................ 1 SAFETY.............................................................................................................. 3 ALL CONTENTS........................................................................................................ 31 SECTION 1 GENERAL INFORMATION....................................................................................... 33 GROUP 1 Precautions for Disassembling and Assembling............................................................ 35 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING................................................................ 35 MAINTENANCE STANDARD TERMINOLOGY............................................................................ 41 GROUP 2 Tightening.............................................................................................. 43 TIGHTENING TORQUE SPECIFICATIONS............................................................................ 43 TORQUE CHART................................................................................................ 45 PIPING JOINT................................................................................................ 48 PERIODIC REPLACEMENT OF PARTS............................................................................... 52 SECTION 2 UPPERSTRUCTURE............................................................................................ 53 GROUP 1 Cab..................................................................................................... 55 REMOVE AND INSTALL CAB...................................................................................... 55 Dimensions of the Cab Glass................................................................................. 69 GROUP 2 Counterweight........................................................................................... 73 REMOVE AND INSTALL COUNTERWEIGHT............................................................................ 73 GROUP 3 Pump Device............................................................................................. 75 REMOVE AND INSTALL PUMP DEVICE.............................................................................. 75 DISASSEMBLE PUMP TRANSMISSION............................................................................... 78 ASSEMBLE PUMP TRANSMISSION.................................................................................. 80 DISASSEMBLE MAIN PUMP....................................................................................... 82 ASSEMBLE MAIN PUMP.......................................................................................... 86 MAINTENANCE STANDARD........................................................................................ 88 DISASSEMBLE REGULATOR (MAIN PUMP)........................................................................... 90 ASSEMBLE REGULATOR (MAIN PUMP).............................................................................. 94 DISASSEMBLE PUMP OF OIL COOLER FAN MOTOR....................................................................100 ASSEMBLE PUMP OF OIL COOLER FAN MOTOR.......................................................................104 MAINTENANCE STANDARD........................................................................................106 DISASSEMBLE REGULATOR (Pump for Driving Oil Cooler Fan Motor) ..............................................108 ASSEMBLE REGULATOR (Pump for Driving Oil Cooler Fan Motor)..................................................112 CONFIGURATION OF PILOT PUMP.................................................................................118 CONFIGURATION OF PUMP FOR LUBRICATING PUMP TRANSMISSION.....................................................120 GROUP 4 Control Valve...........................................................................................123 REMOVE AND INSTALL CONTROL VALVE............................................................................123 DISASSEMBLE MAIN CONTROL VLAVE 1 (5-SPOOL SECTION)..........................................................128 ASSEMBLE MAIN CONTROL VALVE 1 (5-SPOOL SECTION).............................................................132 DISASSEMBLE MAIN CONTROL VALVE 2 (5-SPOOL SECTION)..........................................................138 ASSEMBLE MAIN CONTROL VALVE 2 (5-SPOOL SECTION).............................................................140 DISASSEMBLE MAIN CONTROL VALVE 1 (4-SPOOL SECTION)..........................................................142 ASSEMBLE MAIN CONTROL VALVE 1 (4-SPOOL SECTION).............................................................150 DISASSEMBLE MAIN CONTROL VALVE 2 (4-SPOOL SECTION)..........................................................156 ASSEMBLE MAIN CONTROL VALVE 2 (4-SPOOL SECTION).............................................................158 DISASSEMBLE MANIFOLD........................................................................................160 ASSEMBLE MANIFOLD...........................................................................................162 DISASSEMBLE SWING CONTROL VALVE 1...........................................................................164 ASSEMBLE SWING CONTROL VALVE 1..............................................................................170 DISASSEMBLE SWING CONTROL VALVE 2...........................................................................174 ASSEMBLE SWING CONTROL VALVE 2..............................................................................176 GROUP 5 Swing Device............................................................................................179 REMOVE AND INSTALL SWING DEVICE.............................................................................179 Disassemble Swing Reduction Gear............................................................................184 Assemble Swing Reduction Gear...............................................................................190 DISASSEMBLE SWING MOTOR.....................................................................................194 Assemble Swing Motor........................................................................................198 DISASSEMBLE AND ASSEMBLE SWING PARKING BRAKE RELEASING VALVE................................................202 MAINTENANCE STANDARD........................................................................................204 GROUP 6 Pilot Valve.............................................................................................207 REMOVE AND INSTALL RIGHT PILOT VALVE........................................................................207 REMOVE AND INSTALL LEFT PILOT VALVE.........................................................................211 REMOVE AND INSTALL TRAVEL PILOT VALVE. REMOVE AND INSTALL BUCKET PILOT VALVE (FOR LOADING SHOVEL ONLY)....215 DISASSEMBLE FRONT PILOT VALVES..............................................................................220 ASSEMBLE FRONT PILOT VALVES.................................................................................224 DISASSEMBLE TRAVEL PILOT VALVE..............................................................................228 ASSEMBLE TRAVEL PILOT VALVE.................................................................................232 DISASSEMBLE PILOT VALVE FOR BUCKET OPENING /CLOSING.........................................................238 ASSEMBLE PILOT VALVE FOR BUCKET OPENING/CLOSING.............................................................240 GROUP 7 Pilot Shut-off Valve....................................................................................243 REMOVE AND INSTALL PILOT SHUT-OFF VALVE.....................................................................243 DISASSEMBLE PILOT SHUT-OFF VALVE............................................................................246 ASSEMBLE PILOT SHUT-OFF VALVE...............................................................................248 GROUP 8 Shockless Valve.........................................................................................251 REMOVE AND INSTALL FRONT ATTACHMENT SHOCKLESS VALVE.........................................................251 DISASSEMBLE AND ASSEMBLE THE SHOCKLESS VALVE................................................................253 GROUP 9 Solenoid Valve..........................................................................................255 REMOVE AND INSTALL SOLENOID VALVE...........................................................................255 DISASSEMBLE 2-SPOOL EHC VALVE (BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN).............258 ASSEMBLE 2-SPOOL EHC VALVE (BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN)................260 GROUP 10 Signal Control Valve...................................................................................265 REMOVE AND INSTALL SIGNAL CONTROL VALVE.....................................................................265 PILOT PORT..................................................................................................267 GROUP 11 Oil Cooler Fan Motor...................................................................................269 REMOVE AND INSTALL OIL COOLER FAN MOTOR.....................................................................269 DISASSEMBLE OIL COOLER FAN MOTOR............................................................................272 ASSEMBLE OIL COOLER FAN MOTOR...............................................................................274 SECTION 3 UNDERCARRIAGE.............................................................................................277 GROUP 1 Swing Bearing...........................................................................................279 REMOVE AND INSTALL SWING BEARING............................................................................279 DISASSEMBLE SWING BEARING...................................................................................282 ASSEMBLE SWING BEARING......................................................................................284 GROUP 2 Travel Device...........................................................................................287 REMOVE AND INSTALL TRAVEL DEVICE............................................................................287 DISASSEMBLE TRAVEL REDUCER..................................................................................290 ASSEMBLE TRAVEL REDUCER.....................................................................................296 DISASSEMBLE TRAVEL MOTOR....................................................................................304 ASSEMBLE TRAVEL MOTOR.......................................................................................308 DISASSEMBLE TRAVEL BRAKE VALVE..............................................................................312 ASSEMBLE TRAVEL BRAKE VALVE.................................................................................316 MAITENANCE STANDARD.........................................................................................318 GROUP 3 Center Joint............................................................................................321 REMOVE AND INSTALL CENTER JONT..............................................................................321 DISASSEMBLE CENTER JOINT....................................................................................324 ASSEMBLE CENTER JOINT.......................................................................................326 MAINTENANCE STANDARD........................................................................................330 GROUP 4 Track Adjuster..........................................................................................331 REMOVE AND INSTALL TRACK ADJUSTER...........................................................................331 DISASSEMBLE TRACK ADJUSTER..................................................................................332 ASSEMBLE TRACK ADJUSTER.....................................................................................338 GROUP 5 Front Idler.............................................................................................345 REMOVE AND INSTALL FRONT IDLER..............................................................................345 DISASSEMBLE FRONT IDLER.....................................................................................346 ASSEMBLE FRONT IDLER........................................................................................350 MAINTENANCE STANDARD........................................................................................352 GROUP 6 Upper And Lower Roller..................................................................................353 REMOVE AND INSTALL UPPER ROLLER.............................................................................353 REMOVE AND INSTALL LOWER ROLLER.............................................................................355 DISASSEMBLE UPPER ROLLER....................................................................................358 ASSEMBLE UPPER ROLLER.......................................................................................360 DISASSEMBLE LOWER ROLLER....................................................................................362 ASSEMBLE LOWER ROLLER.......................................................................................364 MAINTENANCE STANDARD........................................................................................366 GROUP 7 Track...................................................................................................369 REMOVE AND INSTALL TRACKS...................................................................................369 MAINTENANCE STANDARD........................................................................................375 SECTION 4 FRONT ATTACHMENT..........................................................................................379 GROUP 1 Front Attachment........................................................................................381 REMOVE AND INSTALL FRONT ATTACHMENT.........................................................................381 REMOVE AND INSTALL BUCKET AND ARM (BACKHOE).................................................................382 REMOVE AND INSTALL BUCKET AND ARM (LOADING SHOVEL)..........................................................390 REMOVE AND INSTALL BOOM (BACKHOE, LOADING SHOVEL)...........................................................394 GREASING (BACKHOE)..........................................................................................398 GREASING (LOADING SHOVEL)...................................................................................399 GROUP 2 Cylinder................................................................................................401 REMOVE AND INSTALL CYLINDER.................................................................................401 DISASSEMBLE CYLINDER........................................................................................435 ASSEMBLE CYLINDER...........................................................................................442 AIR BLEEDING PROCEDURE......................................................................................450 MAINTENANCE STANDARD........................................................................................451 GROUP 3 Bushing and Point.......................................................................................453 REMOVE AND INSTALL BUSHING..................................................................................453 MAINTENANCE STANDARD........................................................................................458 REVISION REQUEST FORM...............................................................................................467
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