Hitachi Ex215 Excavator Technical Troubleshooting Manual (604.06.812) – PDF Download

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Hitachi Ex215 Excavator Technical Troubleshooting Manual (604.06.812)

File Details:

Hitachi Ex215 Excavator Technical Troubleshooting Manual (604.06.812)

• Manual Language:English
• Downloadable:Yes
• Pages: 221
• Size: 2.80 MB
• Format:PDF

HITACHI EX215 EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (604.06.812) – PDF DOWNLOAD:

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Description:

Hitachi Ex215 Excavator Technical Troubleshooting Manual (604.06.812)

TO THE READER
• This manual is written for an experienced technician to provide technical information needed o maintain and repair this machine.
– Be sure to thoroughly read this manual for correct information concerning the service procedures.
– If you have any questions or comments, or if you found any errors regarding the contents of this manual.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this service manual:
– Operator’s Manual
– Spare Parts Catalog
SERVICE MANUAL COMPOSITION
• The complete service manual consists of four books:
– Technical Manual – Operational Principle
– Technical Manual – Troubleshooting
– Excavator Workshop Manual
– Engine Workshop Manual
– The Technical Manual-Operational Principle includes the technical information concerning the operation of main devices and systems.
– The Technical Manual -Troubleshooting includes the technical information needed for operational performance tests, and troubleshooting procedures.
– The Excavator and the Engine Workshop Manuals include information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.

Table Of Contents:

Hitachi Ex215 Excavator Technical Troubleshooting Manual (604.06.812)

TROUBLESHOOTING.....................................................................  1
Introduction........................................................................  2
Section and Group Contents.......................................................... 28
	Section4 - Operating Performance................................................ 29
		Group 1 - Introduction...................................................... 30
			Operational performance test............................................ 30
			Preparation for performance tests....................................... 31
		Group 2 - Standard.......................................................... 32
			Operational Performance standard tables................................. 32
			Main pump P-Q diagram................................................... 36
		Group 3 - Engine test....................................................... 38
			Engine speed............................................................ 38
		Group 4 - Excavator test.................................................... 40
			Travel speed............................................................ 40
			Track revolution speed.................................................. 41
			Mistrack check.......................................................... 42
			Travel parking function check........................................... 43
			Swing speed............................................................. 44
			Swing function drift check.............................................. 45
			Swing motor leakage..................................................... 46
			Swing bearing play...................................................... 47
			Maximum swingable slant angle........................................... 48
			Hydraulic cylinder cycle time........................................... 49
			Dig function drift check................................................ 51
			Control lever operating force........................................... 52
			Control lever stroke.................................................... 53
			Combined boom raise/swing function check................................ 54
		Group 5 - Component test.................................................... 56
			Primary pilot pressure.................................................. 56
			Secondary pilot pressure................................................ 58
			Solenoid valve set pressure............................................. 59
			Main pump delivery pressure............................................. 61
			Main relief valve set pressure.......................................... 62
			Overload relief valve set pressure...................................... 66
			Main pump flow test..................................................... 69
			Swing motor drainage.................................................... 73
			Travel motor drainage................................................... 75
	Section5 - Troubleshooting...................................................... 78
		Group 1 - Diagnosing Procedure.............................................. 80
			Introduction............................................................ 80
			Diagnosing Procedure.................................................... 81
			Dr.EX................................................................... 83
			Dr.EX Start-Up Procedure................................................ 83
			Dr.EX Fault Code........................................................ 84
			Dr.EX Monitoring Function............................................... 85
			Dr.EX Special Function (Service Mode)................................... 86
			Adjustable Data List.................................................... 93
		Group 2 - Component Layout.................................................. 94
			Main Components......................................................... 94
			Electrical System (Overall System)...................................... 95
			Electrical System (Relays).............................................. 96
			Electrical System  (Monitor and Switch Panels).......................... 97
			Pump and Related Parts.................................................. 98
			Control Valve........................................................... 99
			Others Components.......................................................103
		Group 3 - Troubleshooting A.................................................104
			Troubleshooting A Procedure ............................................104
			Fault Codes.............................................................105
			Fault Code 01...........................................................107
			Fault Code 02, 03.......................................................108
			Fault Code 04, 05.......................................................109
			Fault Code 06...........................................................110
			Fault Code 07...........................................................111
			Sensor Operating Range List.............................................112
		Group 4 - Troubleshooting B.................................................114
			Troubleshooting B Procedure.............................................114
			Relationship between Machine Trouble  Symptoms and Parts in Trouble.....115
			Correlation between Trouble  Symptoms and Part Failures.................125
			Engine Troubleshooting..................................................131
			Actuator Control System  Troubleshooting................................145
			Front Attachment Control System  Troubleshooting........................151
			Swing System Troubleshooting............................................163
			Travel System Troubleshooting...........................................166
			Troubleshooting for Other Functions.....................................171
			Engine Speed Adjustment and  Engine Learning............................173
			Exchange Inspection Method..............................................174
		Group 5 - Troubleshooting C.................................................176
			Troubleshooting C Procedure.............................................176
			Malfunction of Coolant Temperature Gauge................................177
			Malfunction of Fuel Gauge...............................................179
			Malfunction of Fuel Level Indicator.....................................181
			Malfunction of Indicator Light Check System.............................183
			Malfunction of Level Check Switch.......................................183
			Malfunction of Engine Oil Level Indicator...............................185
			Malfunction of Coolant Level Indicator..................................187
			Malfunction of Hydraulic Oil Level Indicator............................189
			Malfunction of Alternator Indicator.....................................191
			Malfunction of Engine Oil Pressure Indicator............................193
			Malfunction of Overheat Indicator.......................................195
			Malfunction of Air Filter Restriction Indicator.........................197
			Malfunction of Buzzer...................................................199
			Malfunction of Hour Meter...............................................201
		Group 6 - Electrical System Inspection......................................202
			Precautions for Inspection and  Maintenance.............................202
			Instructions for Disconnecting Connectors...............................204
			Fuse Continuity Test....................................................205
			Inspection and Replacement of Fusible Links.............................206
			Battery Voltage Check...................................................207
			How to Troubleshoot Alternator Malfunctions.............................208
			Continuity Check........................................................209
			Voltage and Current Check...............................................211
			Replacement of Relay....................................................215
		Group 7 - Harness Check.....................................................216
			Circuit Check...........................................................216

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