Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TTLA-0438-EX) – PDF Download

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Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TTLA-0438-EX)

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Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TTLA-0438-EX)

• Manual Language:English
• Pages: 293
• Size: 4.25 MB
• Downloadable:Yes
• Format:PDF

HITACHI EX3600-5 EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (TTLA-0438-EX) – PDF DOWNLOAD:

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Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TTLA-0438-EX)

1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.
2. Operate the machine carefully and always give first priority to safety.
3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

Table of Contents:

Hitachi Ex3600-5 Excavator Technical Troubleshooting Manual (TTLA-0438-EX)

MATERIALS TOP....................................................................................................  0
PERFORMANCE CHECK TROUBLESHOOTING................................................................................  1
SECTION 04 OPERATIONAL PERFORMANCE TEST..........................................................................  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 MOTOR DRIFT CHECK................................................................................. 11
		SWING SPEED.............................................................................................. 12
		SWING FUNCTION DRIFT..................................................................................... 13
		SWING MOTOR LEAKAGE...................................................................................... 14
		MAXIMUM SWINGABLE SLANT ANGLE............................................................................ 15
		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 CHECK............................................................................. 26
		SECONDARY PILOT PRESSURE CHECK........................................................................... 27
		MAIN RELIEF PRESSURE CHECK............................................................................... 29
		OVERLOAD RELIEF VALVE SET PRESSURE....................................................................... 33
		MAIN PUMP FLOW RATE MEASUREMENT.......................................................................... 35
		FAN DRIVE PUMP FLOW RATE MEASUREMENT..................................................................... 43
		SWING MOTOR DRAIN CHECK.................................................................................. 51
		TRAVEL MOTOR DRAIN CHECK................................................................................. 53
	GROUP 5 STANDARD............................................................................................. 56
		OPERATIONAL PERFORMANCE STANDARD......................................................................... 56
		INJECTION PUMP........................................................................................... 59
SECTION 05  TROUBLESHOOTING...................................................................................... 60
	GROUP 1 GENERAL.............................................................................................. 62
		INTRODUCTION............................................................................................. 62
		DIAGNOSING PROCEDURE..................................................................................... 63
	GROUP 2 COMPONENT LAYOUT..................................................................................... 66
		MAIN COMPONENTS.......................................................................................... 66
		CONTROL VALVE............................................................................................ 69
		TRAVEL DEVICE............................................................................................ 71
		SWING DEVICE............................................................................................. 72
		ELECTRICAL COMPONENTS.................................................................................... 73
		PILOT PIPING............................................................................................. 85
	GROUP 3 TROUBLESHOOTING A....................................................................................144
		TROUBLESHOOTING A PROCEDURES.............................................................................144
		HOW TO READ FAULT CODES ON ECM ENGINE DIAGNOSIS SYSTEM...................................................145
	GROUP 4 TROUBLESHOOTING B....................................................................................148
		TROUBLESHOOTING B PROCEDURE..............................................................................148
		RELATIONSHIP BETWEEN MACHINE  TROUBLE AND POTENTIAL PROBLEM  PARTS WHICH MAY CAUSE TROUBLE IF  FAILED....149
		ENGINE SYSTEM TROUBLESHOOTING............................................................................155
		ACTUATOR SYSTEM TROUBLESHOOTING..........................................................................171
		FRONT ATTACHMENT SYSTEM TROUBLESHOOTING..................................................................177
		SWING SYSTEM TROUBLESHOOTING.............................................................................189
		TRAVEL SYSTEM TROUBLESHOOTING............................................................................193
		OTHER SYSTEM TROUBLESHOOTING.............................................................................201
		DIAGNOSIS BY FLASHING INDICATORS.........................................................................229
	GROUP 5 TROUBLESHOOTING C....................................................................................232
		TROUBLESHOOTING C PROCEDURE..............................................................................232
		MALFUNCTION OF TACHOMETER................................................................................233
		MALFUNCTION OF COOLANT TEMPERATURE  GAUGE................................................................235
		MALFUNCTION OF HYDRAULIC OIL TEMPERATURE  GAUGE..........................................................237
		MALFUNCTION OF FUEL GAUGE................................................................................239
		MALFUNCTION OF PUMP TRANSMISSION  OIL PRESSURE INDICATOR.................................................241
		MALFUNCTION OF ENGINE OIL PRESSURE  INDICATOR............................................................243
		MALFUNCTION OF OVERHEAT INDICATOR........................................................................245
		MALFUNCTION OF FUEL LEVEL INDICATOR......................................................................247
		MALFUNCTION OF HYDRAULIC OIL  LEVEL INDICATOR............................................................249
		MALFUNCTION OF COOLANT LEVEL INDICATOR...................................................................251
		MALFUNCTION OF AUTO-LUBRICATION  INDICATOR...............................................................253
		MALFUNCTION OF PUMP CONTAMINATION  INDICATOR.............................................................255
		MALFUNCTION OF AIR CLEANER RESTRICTION  INDICATOR........................................................257
		MALFUNCTION OF LADDER INDICATOR..........................................................................259
		MALFUNCTION OF STOP VALVE INDICATOR......................................................................261
		MALFUNCTION OF FAST-FILLING PANEL INDICATOR..............................................................263
		MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR.............................................................265
		MALFUNCTION OF COOLANT LEVEL INDICATOR...................................................................266
		MALFUNCTION OF ENGINE OIL LEVEL  INDICATOR...............................................................267
		MALFUNCTION OF EMERGENCY ENGINE STOP INDICATOR...........................................................268
		MALFUNCTION OF FAST TRAVEL MODE  INDICATOR...............................................................269
		MALFUNCTION OF SLOW TRAVE MODE INDICATOR.................................................................270
		MALFUNCTION OF AUTO-IDLE INDICATOR.......................................................................271
		MALFUNCTION OF ALTERNATOR INDICATOR......................................................................272
		MALFUNCTION OF LEVEL CHECK  SWITCH.......................................................................273
		MALFUNCTION OF INDICATOR LIGHT CHECK SWITCH..............................................................273
		MALFUNCTION OF HOUR METER................................................................................274
		MALFUNCTION OF BUZZER....................................................................................275
	GROUP 6 ELECTRICAL SYSTEM INSPECTION.........................................................................276
		PRECAUTIONS FOR INSPECTION AND MAINTENANCE...............................................................276
		BATTERY VOLTAGE CHECK....................................................................................278
		FUSE INSPECTION..........................................................................................279
		FUSIBLE LINK INSPECTION..................................................................................283
		ALTERNATOR CHECK.........................................................................................284
		VOLTAGE CHECK............................................................................................285
		CONTINUITY CHECK.........................................................................................292

Please Note:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.