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Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TT146E-01) – PDF Download
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- Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual
- Part No:TT146E-01
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Description
Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TT146E-01)
File Details:
Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TT146E-01)
- Manual Language:English
- Pages: 366
- Size: 18.8 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX3600-5 EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (TT146E-01) – PDF DOWNLOAD:
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Description:
Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TT146E-01)
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 redeliver 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 Ex3600-5 Excavator Technical Troubleshooting Manual (TT146E-01)
EX3600-5 Technical Manual (Troubleshooting)..................................................................... 1 INTRODUCTION................................................................................................. 3 TO THE READER............................................................................................ 3 ADDITIONAL REFERENCES.................................................................................... 3 MANUAL COMPOSITION....................................................................................... 3 PAGE NUMBER.............................................................................................. 3 SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS............................................................... 4 UNITS USED............................................................................................... 4 SAFETY....................................................................................................... 5 RECOGNIZE SAFETY INFORMATION............................................................................. 5 UNDERSTAND SIGNAL WORDS.................................................................................. 5 FOLLOW SAFETY INSTRUCTIONS............................................................................... 6 PREPARE FOR EMERGENCIES.................................................................................. 6 WEAR PROTECTIVE CLOTHING................................................................................. 7 PROTECT AGAINST NOISE.................................................................................... 7 INSPECT MACHINE.......................................................................................... 7 USE HANDHOLDS AND STEPS.................................................................................. 8 ADJUST THE OPERATOR'S SEAT............................................................................... 8 FASTEN YOUR SEAT BELT.................................................................................... 9 MOVE AND OPERATE MACHINE SAFELY.......................................................................... 9 OPERATE ONLY FROM OPERATOR'S SEAT........................................................................ 10 HANDLE STARTING AIDS SAFELY.............................................................................. 10 JUMP STARTING............................................................................................ 10 KEEP RIDERS OFF MACHINE.................................................................................. 11 PROVIDE SIGNALS FOR FOBS INVOLV- ING MULTIPLE NUMBERS OF MACHINES........................................ 11 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN................................................................ 11 DRIVE MACHINE SAFELY..................................................................................... 12 AVOID INJURY FROM ROLLAWAY ACCIDENTS..................................................................... 13 AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS.......................................................... 14 AVOID TIPPING............................................................................................ 15 AVOID POWER LINES........................................................................................ 16 OBJECT HANDLING.......................................................................................... 16 PROTECT AGAINST FLYING DEBRIS............................................................................ 17 PARK MACHINE SAFELY...................................................................................... 17 HANDLE FLUIDS SAFELY ••••AVOID FIRES..................................................................... 18 PRACTICE SAFE MAINTENANCE................................................................................ 19 WARN OTHERS OF SERVICE WORK.............................................................................. 20 SUPPORT MACHINE PROPERLY................................................................................. 20 STAY CLEAR OF MOVING PARTS............................................................................... 20 PREVENT PARTS FROM FLYING................................................................................ 21 STORE ATTACHMENTS SAFELY................................................................................. 21 USE TOOLS PROPERLY....................................................................................... 21 PREVENT BURNS............................................................................................ 22 REPLACE RUBBER HOSES PERIODICALLY........................................................................ 22 AVOID HIGH-PRESSURE FLUIDS............................................................................... 23 PREVENT FIRES............................................................................................ 24 EVACUATING IN CASE OF FIRE............................................................................... 25 BEWARE OF EXHAUST FUMES.................................................................................. 26 AVOID HEATING NEAR PRESSURIZED FLUID LINES............................................................... 26 AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS................................................. 26 REMOVE PAINT BEFORE WELDING OR HEATING................................................................... 27 PREVENT BATTERY EXPLOSIONS............................................................................... 27 SERVICE AIR CONDITIONING SYSTEM SAFELY................................................................... 28 AVOID HARMFUL ASBESTOS DUST.............................................................................. 28 HANDLE CHEMICAL PRODUCTS SAFELY.......................................................................... 29 DISPOSE OF WASTE PROPERLY................................................................................ 29 BEFORE RETURNING THE MACHINE TO THE CUSTOMER............................................................. 30 CONTENTS..................................................................................................... 31 SECTION 4 ERATIONAL PERFORMANCE TEST....................................................................... 33 Introduction............................................................................................. 35 OPERATIONAL PERFORMANCE TEST......................................................................... 35 PREPARATION FOR PERFORMANCE TESTS.................................................................... 36 Engine Test.............................................................................................. 37 ENGINE SPEED......................................................................................... 37 Excavator Test........................................................................................... 39 TRAVEL SPEED......................................................................................... 39 TRACK REVOLUTION SPEED............................................................................... 40 MISTRACK............................................................................................. 41 TRAVEL MOTOR DRIFT CHECK............................................................................. 42 SWING SPEED.......................................................................................... 43 SWING FUNCTION DRIFT................................................................................. 44 SWING MOTOR LEAKAGE.................................................................................. 45 MAXIMUM SWINGABLE SLANT ANGLE........................................................................ 46 SWING BEARING PLAY................................................................................... 48 HYDRAULIC CYLINDER CYCLE TIME........................................................................ 50 CYLINDER DRIFT....................................................................................... 52 CONTROL LEVER OPERATING FORCE........................................................................ 53 CONTROL LEVER STROKE................................................................................. 54 BOOM RAISE/SWING COMBINED OP- ERATION CHECK.......................................................... 55 Component Test........................................................................................... 57 PRIMARY PILOT PRESSURE CHECK......................................................................... 57 SECONDARY PILOT PRESSURE CHECK....................................................................... 58 MAIN RELIEF PRESSURE CHECK........................................................................... 60 OVERLOAD RELIEF VALVE SET PRES- SURE................................................................. 64 MAIN PUMP FLOW RATE MEASUREMENT...................................................................... 66 FAN DRIVE PUMP FLOW RATE MEAS- UREMENT............................................................... 74 SWING MOTOR DRAIN CHECK.............................................................................. 82 TRAVEL MOTOR DRAIN CHECK............................................................................. 84 Standard................................................................................................. 87 OPERATIONAL PERFORMANCE STAN- DARD................................................................... 87 INJECTION PUMP....................................................................................... 90 SECTION 5 TROUBLESHOOTING.................................................................................... 93 General.................................................................................................. 95 INTRODUCTION......................................................................................... 95 DIAGNOSING PROCEDURE................................................................................. 96 Cross Reference Table.................................................................................... 99 Electrical Circuit Diagram 1/3....................................................................... 99 Electrical Circuit Diagram 2/3.......................................................................102 Electrical Circuit Diagram 3/3.......................................................................105 Hydraulic Circuit Diagram............................................................................109 Component Layout.........................................................................................115 MAIN COMPONENTS......................................................................................115 CONTROL VALVE........................................................................................118 TRAVEL DEVICE........................................................................................120 SWING DEVICE.........................................................................................121 ELECTRICAL COMPONENTS................................................................................122 PILOT PIPING.........................................................................................134 Troubleshooting A........................................................................................193 TROUBLESHOOTING A PROCEDURES.........................................................................193 HOW TO READ FAULT CODES ON ECM ENGINE DIAGNOSIS SYSTEM...............................................194 Troubleshooting B........................................................................................197 TROUBLESHOOTING B PROCEDURE..........................................................................197 RELATIONSHIP ETWEEN MACHINE TROUBLE AND POTENTIAL PROBLEM PARTS WHICH MAY CAUSE TROUBLE IF FAILED....198 ENGINE SYSTEM TROUBLESHOOTING........................................................................204 ACTUATOR SYSTEM TROUBLESHOOT- ING....................................................................220 FRONT ATTACHMENT SYSTEM TROU- BLESHOOTING............................................................226 SWING SYSTEM TROUBLESHOOTING.........................................................................238 TRAVEL SYSTEM TROUBLESHOOTING........................................................................242 OTHER SYSTEM TROUBLESHOOTING.........................................................................250 DIAGNOSIS BY FLASHING INDICATORS.....................................................................278 Troubleshooting C........................................................................................281 TROUBLESHOOTING C PROCEDURE..........................................................................281 MALFUNCTION OF TACHOMETER............................................................................282 MALFUNCTION OF COOLANT TEM- PERATURE GAUGE...........................................................284 MALFUNCTION OF HYDRAULIC OIL TEM- PERATURE GAUGE.....................................................286 MALFUNCTION OF FUEL GAUGE............................................................................288 MALFUNCTION OF PUMP TRANSMIS- SION OIL PRESSURE INDICATOR............................................290 MALFUNCTION OF ENGINE OIL PRES- SURE INDICATOR.......................................................292 MALFUNCTION OF OVERHEAT INDICA- TOR..................................................................294 MALFUNCTION OF FUEL LEVEL INDICA- TOR................................................................296 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR.........................................................298 MALFUNCTION OF COOLANT LEVEL IN- DICATOR.............................................................300 MALFUNCTION OF AUTO-LUBRICATION INDICATOR............................................................302 MALFUNCTION OF PUMP CONTAMINA- TION INDICATOR........................................................304 MALFUNCTION OF AIR CLEANER RE- STRICTION INDICATOR...................................................306 MALFUNCTION OF LADDER INDICATOR......................................................................308 MALFUNCTION OF STOP VALVE INDI- CATOR................................................................310 MALFUNCTION OF FAST-FILLING PANEL INDICATOR..........................................................312 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR.........................................................314 MALFUNCTION OF COOLANT LEVEL IN- DICATOR.............................................................315 MALFUNCTION OF ENGINE OIL LEVEL INDICATOR............................................................316 MALFUNCTION OF EMERGENCY ENGINE STOP INDICATOR.......................................................317 MALFUNCTION OF FAST TRAVEL MODE INDICATOR............................................................318 MALFUNCTION OF SLOW TRAVE MODE INDICATOR.............................................................319 MALFUNCTION OF AUTO-IDLE INDICA- TOR.................................................................320 MALFUNCTION OF ALTERNATOR INDI- CATOR................................................................321 MALFUNCTION OF LEVEL CHECK SWITCH....................................................................322 MALFUNCTION OF HOUR METER............................................................................323 MALFUNCTION OF BUZZER................................................................................324 MALFUNCTION OF ENTRANCE LIGHT INDICATOR..............................................................325 MALFUNCTION OF MAINTENANCE WORK LIGHT INDICATOR......................................................326 MALFUNCTION OF DOWNLOAD INDICA- TOR..................................................................327 MALFUNCTION OF PREHEAT INDICATOR.....................................................................328 MALFUNCTION OF ENGINE STOP INDI- CATOR...............................................................330 MALFUNCTION OF ENGINE WARNING INDICATOR..............................................................331 MALFUNCTION OF ENGINE EXHAUST GAS TEMPERATURE INDICATOR..............................................332 Electrical System Inspection.............................................................................335 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...........................................................335 BATTERY VOLTAGE CHECK................................................................................337 FUSE INSPECTION......................................................................................338 FUSIBLE LINK INSPECTION..............................................................................342 ALTERNATOR CHECK.....................................................................................343 VOLTAGE CHECK........................................................................................344 CONTINUITY CHECK.....................................................................................351 SERVICE MANUAL REVISION REQUEST FORM.........................................................................355 ATTACHED DIAGRAM LIST........................................................................................356 1. ELECTRICAL CIRCUIT DIAGRAM 1/3-1......................................................................357 2. ELECTRICAL CIRCUIT DIAGRAM 1/3-2......................................................................358 3. ELECTRICAL CIRCUIT DIAGRAM 2/3-1......................................................................359 4. ELECTRICAL CIRCUIT DIAGRAM 2/3-2......................................................................360 5. ELECTRICAL CIRCUIT DIAGRAM 2/3-3......................................................................361 6. ELECTRICAL CIRCUIT DIAGRAM 3/3-1......................................................................362 7. ELECTRICAL CIRCUIT DIAGRAM 3/3-2......................................................................363 8. CONNECTORS............................................................................................364 9. HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)...................................................................365 10. HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)...........................................................366
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
