Hitachi EX1200-5C Excavator Technical Troubleshooting Manual (TT18EE-00) – PDF Download

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:

Image Preview:

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

Please Note:

⦁ This is the SAME MANUAL used by the dealerships to diagnose your vehicle
⦁ No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
⦁ Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
⦁ So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com