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Hitachi EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00) – PDF Download
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- Hitachi EX1200-5C Excavator Technical Troubleshooting Manual
- Vol No:TT18EE-00
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Description
Hitachi EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00)
File Details:
Hitachi EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00)
- Manual Language:English
- Pages: 353
- Size: 6.29 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX1200-5C EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (TT18EE-00) – PDF DOWNLOAD:
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Description:
Hitachi EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00)
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 EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00)
COVER.................................................................................................................................................................. 1 INTRODUCTION........................................................................................................................................................... 2 SAFETY................................................................................................................................................................. 4 ALL CONTENTS........................................................................................................................................................... 32 SECTION 4 OPERATIONAL PERFORMANCE TEST............................................................................................................................. 34 GROUP 1 INTRODUCTION........................................................................................................................................... 36 OPERATIONAL PERFORMANCE TESTS.............................................................................................................................. 36 PREPARATION FOR PERFORMANCE TESTS.......................................................................................................................... 37 GROUP 2 STANDARD............................................................................................................................................... 38 OPERATIONAL PERFORMANCE STANDARD........................................................................................................................... 38 MAIN PUMP P-Q DIAGRAM...................................................................................................................................... 41 OIL COOLER FAN MOTOR DRIVE PUMP P-Q DIAGRAM................................................................................................................ 41 INJECTION PUMP............................................................................................................................................. 42 GROUP 3 ENGINE TEST............................................................................................................................................ 44 ENGINE SPEED............................................................................................................................................... 44 GROUP 4 EXCAVATOR TEST......................................................................................................................................... 46 TRAVEL SPEED............................................................................................................................................... 46 TRACK REVOLUTION SPEED..................................................................................................................................... 47 MISTRACK................................................................................................................................................... 48 TRAVEL PARKING FUNCTION.................................................................................................................................... 49 SWING SPEED................................................................................................................................................ 50 SWING FUNCTION DRIFT....................................................................................................................................... 51 SWING MOTOR LEAKAGE........................................................................................................................................ 53 MAXIMUM SWINGABLE SLANT ANGLE.............................................................................................................................. 54 SWING BEARING PLAY......................................................................................................................................... 55 HYDRAULIC CYLINDER CYCLE TIME.............................................................................................................................. 57 CYLINDER DRIFT............................................................................................................................................. 59 CONTROL LEVER OPERATING FORCE.............................................................................................................................. 60 CONTROL LEVER STROKE....................................................................................................................................... 61 BOOM RAISE/SWING COMBINED OPERATION CHECK................................................................................................................. 62 GROUP 5 COMPONENT TEST......................................................................................................................................... 64 PRIMARY PILOT PRESSURE..................................................................................................................................... 64 SECONDARY PILOT PRESSURE................................................................................................................................... 66 SOLENOID VALVE SET PRESSURE................................................................................................................................ 67 MAIN PUMP DELIVERY PRESSURE................................................................................................................................ 70 MAIN RELIEF VALVE SET PRESSURE............................................................................................................................. 71 OVERLOAD RELIEF VALVE SET PRESSURE........................................................................................................................ 75 MAIN PUMP FLOW RATE MEASUREMENT............................................................................................................................ 79 OIL COOLER FAN MOTOR DRIVE PUMP FLOW RATE MEASUREMENT...................................................................................................... 85 SWING MOTOR DRAINAGE....................................................................................................................................... 91 TRAVEL MOTOR DRAINAGE...................................................................................................................................... 93 SECTION 5 TROUBLESHOOTING.......................................................................................................................................... 98 GROUP 1 GENERAL................................................................................................................................................100 INTRODUCTION...............................................................................................................................................100 DIAGNOSING PROCEDURE.......................................................................................................................................101 BUILT-IN DIAGNOSING SYSTEM OPERATION.......................................................................................................................103 BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST..................................................................................................................105 BINARY NUMBER BIT LIST.....................................................................................................................................110 MAIN CONTROLLER FAULT CODE LIST............................................................................................................................113 GROUP 2 CROSS REFERENCE TABLE..................................................................................................................................116 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................116 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)........................................................................................................................121 HYDRAULIC CURCUIT DIAGRAM (LOADING SHOVEL).................................................................................................................123 GROUP 3 COMPONENT LAYOUT.......................................................................................................................................126 MAIN COMPONENTS ...........................................................................................................................................126 ELECTRICAL SYSTEM COMPONENTS (1)...........................................................................................................................127 ELECTRICAL SYSTEM COMPONENTS (2)...........................................................................................................................128 ELECTRICAL SYSTEM COMPONENTS (3)...........................................................................................................................133 ELECTRICAL SYSTEM COMPONENTS (4)...........................................................................................................................134 ON AND AROUND PUMPS........................................................................................................................................135 MAIN CONTROL VALVE.........................................................................................................................................137 SWING CONTROL VALVE........................................................................................................................................141 SIGNAL CONTROL VALVE.......................................................................................................................................146 OTHERS.....................................................................................................................................................155 GROUP 4 TROUBLESHOOTING A......................................................................................................................................156 TROUBLESHOOTING A PROCEDURE................................................................................................................................156 MAIN CONTROLLER FAULT CODE LIST............................................................................................................................157 MAIN CONTROLLER A..........................................................................................................................................159 FAULT CODE 01 ABNORMAL EEPROM FAULT CODE 02 ABNORMAL RAM FAULT CODE 03 ABNORMAL A/D CONVERSION.........................................................159 FAULT CODE 04 ABNORMAL SENSOR VOLTAGE..................................................................................................................159 FAULT CODE 05 ABNORMAL ENGINE SPEED....................................................................................................................160 FAULT CODE 06 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND MAIN CONTROLLER B)...................................................161 FAULT CODE 07 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND DLU, OR BETWEEN MAIN CONTROLLER A AND BUILT-IN DIAGNOSING SYSTEM)....162 FAULT CODE 08 ABNORMAL FRONT PILOT PRESSURE FAULT CODE 09 ABNORMAL TRAVEL PILOT PRESSURE...............................................................163 FAULT CODE 10 ABNORMAL ENGINE CONTROL DIAL ANGLE.......................................................................................................165 FAULT CODE 11 ABNORMAL PUMP 1 DELIVERY PRESSURE FAULT CODE 12 ABNORMAL PUMP 2 DELIVERY PRESSURE FAULT CODE 13 ABNORMAL PUMP 3 DELIVERY PRESSURE........167 FAULT CODE 14 ABNORMAL ENGINE EXHAUST GAS TEMPERATURE..................................................................................................168 FAULT CODE 25 ABNORMAL OIL TEMPERATURE SENSOR..........................................................................................................169 MAIN CONTROLLER B..........................................................................................................................................170 FAULT CODE 31 ABNORMAL EEPROM FAULT CODE 32 ABNORMAL RAM FAULT CODE 33 ABNORMAL A/D CONVERSION.........................................................170 FAULT CODE 34 ABNORMAL SENSOR VOLTAGE..................................................................................................................170 FAULT CODE 37 ABNORMAL MAIN CONTROLLER B RECEPTION (BETWEEN MAIN CONTROLLER B AND BUILT-IN DIAGNOSING SYSTEM)..........................................171 SENSOR ACTIVATING RANGE................................................................................................................................172 GROUP 5 TROUBLESHOOTING B......................................................................................................................................174 TROUBLESHOOTING B PROCEDURE................................................................................................................................174 CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES.....................................................................................................175 ENGINE SYSTEM TROUBLESHOOTING..............................................................................................................................187 ALL ACTUATOR SYSTEM TROUBLESHOOTING........................................................................................................................213 FRONT ATTACHMENT SYSTEM TROUBLESHOOTING....................................................................................................................221 SWING SYSTEM TROUBLESHOOTING...............................................................................................................................235 TRAVEL SYSTEM TROUBLESHOOTING..............................................................................................................................238 OTHER SYSTEM TROUBLESHOOTING...............................................................................................................................245 WORK AFTER REPLACING COMPONENTS............................................................................................................................269 ADD COMPRESSOR OIL.........................................................................................................................................269 CHARGE AIR CONDITIONER WITH REFRIGERANT....................................................................................................................270 GROUP 6 TROUBLESHOOTING C......................................................................................................................................278 TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE..................................................................................................278 MALFUNCTION OF COOLANT TEMPERATURE GAUGE...................................................................................................................279 MALFUNCTION OF FUEL GAUGE..................................................................................................................................281 MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM................................................................................................................283 MALFUNCTION OF OVERHEAT INDICATOR..........................................................................................................................285 MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR...........................................................................................................287 MALFUNCTION OF FUEL LEVEL INDICATOR........................................................................................................................289 MALFUNCTION OF PREHEAT INDICATOR...........................................................................................................................291 MALFUNCTION OF DOWNLOAD INDICATOR..........................................................................................................................292 MALFUNCTION OF ALTERNATOR INDICATOR........................................................................................................................293 MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR...............................................................................................................295 MALFUNCTION OF PUMP TRANSMISSION OIL PRESSURE INDICATOR....................................................................................................297 MALFUNCTION OF ENGINE EXHAUST GAS TEMPERATURE INDICATOR...................................................................................................299 MALFUNCTION OF ENGINE OIL LEVEL INDICATOR..................................................................................................................301 MALFUNCTION OF COOLANT LEVEL INDICATOR.....................................................................................................................303 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR...............................................................................................................305 MALFUNCTION OF AUTO-LUBRICATION INDICATOR..................................................................................................................309 MALFUNCTION OF ENGINE STOP INDICATOR.......................................................................................................................311 MALFUNCTION OF ENGINE WARNING INDICATOR....................................................................................................................313 MALFUNCTION OF QUICK-IDLE INDICATOR........................................................................................................................315 MALFUNCTION OF AUTO-IDLE INDICATOR.........................................................................................................................317 MALFUNCTION OF HOURMETER...................................................................................................................................319 MALFUNCTION OF BUZZER......................................................................................................................................321 MALFUNCTION OF LIQUID CRYSTAL DISPLAY (LCD)................................................................................................................323 MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION............................................................................................................325 GROUP 7 TROUBLESHOOTING D......................................................................................................................................328 TROUBLESHOOTING D PROCEDURES...............................................................................................................................328 HOW TO READ FAULT CODES ON ECM ENGINE DIAGNOSIS SYSTEM.....................................................................................................329 GROUP 8 ELECTRICAL SYSTEM INSPECTION...........................................................................................................................332 PRECAUTIONS FOR INSPECTION AND MAINTENANCE.................................................................................................................332 INSPECTIONS FOR DISCONNECTING CONNECTORS...................................................................................................................334 FUSE INSPECTION............................................................................................................................................335 FUSIBLE LINK INSPECTION....................................................................................................................................338 BATTERY VOLTAGE CHECK......................................................................................................................................339 ALTERNATOR CHECK...........................................................................................................................................339 VOLTAGE CHECK..............................................................................................................................................341 CONTINUITY CHECK...........................................................................................................................................348 REVISION REQUEST FORM..............................................................................................................................................352 ATTACHED DIAGRAM LIST..............................................................................................................................................353
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