Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX) – PDF Download

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Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)

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Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)

• Manual Language:English
• Pages: 283
• Size: 2.48 MB
• Downloadable:Yes
• Format:PDF

HITACHI EX1200-5 TECHNICAL TROUBLESHOOTING MANUAL (TTLA-435-EX) – PDF DOWNLOAD:

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Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)

1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.
3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows:

Table Of Contents:

Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)

MATERIALS TOP......................................................  0
Performance Check & Troubleshooting................................  1
SECTION 4 OPERATIONAL PERFORMANCE TEST.............................  2
	CONTENTS.......................................................  2
	Group 1 Introduction...........................................  4
		Operational Performance Tests..............................  4
		Preparation for Performance Tests..........................  5
	Group 2 Engine Test............................................  6
		Engine Speed...............................................  6
	Group 3 Excavator Test.........................................  8
		Travel Speed...............................................  8
		Track Revolution Speed.....................................  9
		Mistrack................................................... 10
		Travel Parking Function.................................... 11
		Swing Speed................................................ 12
		Swing Function Drift....................................... 13
		Swing Motor Leakage........................................ 15
		Maximum Swingable Slant Angle.............................. 16
		Swing Bearing Play......................................... 17
		Hydraulic Cylinder Cycle Time.............................. 19
		Cylinder Drift............................................. 21
		Control Lever Operating Force.............................. 22
		Control Lever Stroke....................................... 23
		Boom Raise/Swing Combined Operation Check.................. 24
	Group 4 Component Test......................................... 26
		Primary Pilot Pressure..................................... 26
		Secondary Pilot Pressure................................... 28
		Solenoid Valve Set Pressure................................ 29
		Main Pump Delivery Pressure................................ 32
		Main Relief Valve Set Pressure............................. 33
		Overload Relief Valve Set Pressure......................... 37
		Main Pump Flow Rate Measurement............................ 41
		Oil Cooler Fan Motor Drive Pump Flow Rate Measurement...... 47
		Swing Motor Drainage....................................... 53
		Travel Motor Drainage...................................... 55
	Group 5 Standard............................................... 58
		Operational Performance Standard........................... 58
		Main Pump P-Q Diagram...................................... 61
		Oil Cooler Fan Motor Drive Pump P-Q Diagram................ 61
		Injection Pump............................................. 62
SECTION 5 TROUBLESHOOTING.......................................... 64
	CONTENTS....................................................... 64
	Group 1 General................................................ 66
		Introduction............................................... 66
		Diagnosing Procedure....................................... 67
		Built-In Diagnosing System Operation....................... 69
		Built-In Diagnosing Function Display List.................. 71
		Binary Number Bit List..................................... 76
		Main Controller Fault Code List ........................... 79
	Group 2 Component Layout....................................... 82
		Main Components............................................ 82
		Electrical System Components (1)........................... 83
		Electrical System Components (2)........................... 84
		Electrical System Components (3)........................... 85
		Electrical System Components (4)........................... 86
		On and Around Pumps........................................ 87
		Main Control Valve......................................... 89
		Swing Control Valve........................................ 93
		Signal Control Valve....................................... 98
		Others.....................................................107
	Group 3 Troubleshooting A......................................108
		Troubleshooting A Procedure................................108
		Main Controller Fault Code List............................109
		Main Controller A..........................................111
		Fault Code 01, 02, 03......................................111
		Fault Code 04..............................................111
		Fault Code 05..............................................112
		Fault Code 06..............................................113
		Fault Code 07..............................................114
		Fault Code 08, 09..........................................115
		Fault Code 10..............................................117
		Fault Code 11, 12, 13......................................119
		Fault Code 14..............................................120
		Fault Code 25..............................................121
		Main Controller B..........................................122
		Fault Code 31, 32, 33......................................122
		Fault Code 34..............................................122
		Fault Code 37..............................................123
		Sensor Activating Range....................................124
	Group 4 Troubleshooting B......................................126
		Troubleshooting B Procedure................................126
		Correlation between Trouble Symptoms and Part Failures.....127
		Engine System Troubleshooting..............................139
		All Actuator System Troubleshooting........................165
		Front Attachment System Troubleshooting....................173
		Swing System Troubleshooting...............................187
		Travel System Troubleshooting..............................190
		Other System Troubleshooting...............................197
	Group 5 Troubleshooting C......................................212
		Troubleshooting C Procedure................................212
		Malfunction of Coolant Temperature Gauge...................213
		Malfunction of Fuel Gauge..................................215
		Malfunction of Indicator Light Check System................217
		Malfunction of Overheat Indicator..........................219
		Malfunction of Air Cleaner Restriction Indicator...........221
		Malfunction of Fuel Level Indicator........................223
		Malfunction of Preheat Indicator...........................225
		Malfunction of Download Indicator..........................226
		Malfunction of Alternator Indicator........................227
		Malfunction of Engine Oil Pressure Indicator...............229
		Malfunction of Pump Transmission Oil Pressure Indicator....231
		Malfunction of Engine Exhaust Gas Temperature Indicator....233
		Malfunction of Engine Oil Level Indicator..................235
		Malfunction of Coolant Level Indicator.....................237
		Malfunction of Hydraulic Oil Level Indicator...............239
		Malfunction of Auto-Lubrication Indicator..................243
		Malfunction of Engine Stop Indicator.......................245
		Malfunction of Engine Warning Indicator....................247
		Malfunction of Quick-Idle Indicator........................249
		Malfunction of Auto-Idle Indicator.........................251
		Malfunction of Hour Meter..................................253
		Malfunction of Buzzer......................................255
		Malfunction of LCD.........................................257
		Malfunction of Engine Troubleshooting Operation............259
	Group 6 Troubleshooting D......................................262
		Troubleshooting D Procedures...............................262
		How to Read Fault Codes on ECM Engine Diagnosis System.....263
	Group 7 Electrical System Inspection...........................266
		Precautions for Inspection and Maintenance.................266
		Instructions for Disconnecting Connectors..................268
		Fuse Inspection............................................269
		Fusible Link Inspection....................................272
		Battery Voltage Check......................................272
		Alternator Check...........................................273
		Voltage Check..............................................275
		Continuity Check...........................................282

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