Hitachi Hydraulic Excavator EX3600-7B Tier 4 Final Cummins engine Operational Technical Manual PN:TOKFB91

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Hitachi Hydraulic Excavator EX3600-7B Tier 4 Final Cummins engine Operational Technical Manual PN:TOKFB91 – PDF DOWNLOAD

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Hitachi Hydraulic Excavator EX3600-7B Tier 4 Final Cummins engine Operational Technical Manual PN:TOKFB91 – PDF DOWNLOAD

Language :English
Pages :1424
Downloadable : Yes
File Type : PDF

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DESCRIPRION:

Hitachi Hydraulic Excavator EX3600-7B Tier 4 Final Cummins engine Operational Technical Manual PN:TOKFB91 – PDF DOWNLOAD

• This manual consists the Technical Manual and the Workshop Manual.
• Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, 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 Hydraulic Excavator EX3600-7B Tier 4 Final Cummins engine Operational Technical Manual PN:TOKFB91 – PDF DOWNLOAD

TOKFB91-EN-00 1
INTRODUCTION 3
SYMBOL AND ABBREVIATION 5
SECTION AND GROUP CONTENTS 7
SECTION 1 GENERAL 9
Group 1 Specifications 11
Specifications 11
Working Range 12
Group 2 Component Layout 15
Main Component (Overview) 15
Main Component (Loading Shovel) 16
Electrical System (Overview) 17
Electrical System (Around Cab Bed) 18
Electrical System (In Cab) 19
Electrical System (Around Battery) 22
Electrical System (Relay Box) 23
Electrical System (Electrical Equipment Box) 24
Electrical System (Relay Layout of Electrical Equipment Box) 25
Electrical System (LED Layout of Contamination Sensor Amplifier) 26
Electrical System (Monitoring Controller Box) 27
Electrical System (Pump Compartment Controller Box) 28
Electrical System (Angle Sensor) 29
Engine 30
Air Cleaner 31
Around Radiator 32
Water Tank 33
Around Pump 34
Fuel Cooler, Pump Transmission Oil Cooler 36
Air Fan 37
Urea SCR System 38
Fuel Tank 40
Folding Stairway 41
Around Oil Cooler 44
Auto-Lubrication Device 45
Hydraulic Oil Tank 46
Control Valve 47
Pilot Panel 51
EDQR Valve 52
Fast-Filling System 53
Fast-Filling Panel 54
Swing Device 55
Center Joint 56
Undercarriage 57
Travel Device 58
Group 3 Component Specifications 59
Engine 59
Heat Exchanger 63
Battery 64
Hydraulic Component 65
Electrical Component 69
SECTION 2 SYSTEM 75
Group 1 Controller 77
Outline 77
MCU: Monitor Control Unit (Alarm Monitor and Sub-Control System Control Unit) 82
ELUF: Electric Lever Control Unit for Front (Electric Control Lever Controller for Controlling Front Attachment Operation) 88
ELUT: Electric Lever Control Unit for Travel (Electric Control Lever Controller for Controlling Travel Operation) 92
PFU: Pump Flow Control Unit (Pump Flow Rate Control Controller) 96
IDU: Information Display Unit (Information Display Controller) 99
ECM: Engine Control Module (Engine Controller) 106
DLU: Data Logging Unit 108
CSU: Contamination Sensing Unit 110
HMU: Hydraulic System Monitoring Unit 112
PMU: Pump Monitoring Unit 114
EHU: Engine Heat Balance Monitoring Unit (Engine Cooling System Monitoring Unit) 116
ODR: Operation Data Recorder 118
BPU: Basic Performance Monitoring Unit 120
Group 2 Control System 123
Outline 123
Engine Control 125
Pump Control 134
Sub-Control System Control 148
Fast-Filling Panel Lower Control 150
Other Control 164
Folding Stairway Control 164
Travel Mode Control 168
Cab Bed Pressurization Control 172
Group 3 ELU System 177
Outline 177
Pilot Shut-Off Control 178
Boom Lower Flow Rate Regeneration Control 180
Cylinder Stroke End Shock Prevention Control 182
Adjuster Cylinder End Travel Limitation Control 184
Swing Stop Control 186
Group 4 Hydraulic System 189
Outline 189
Pilot Circuit 190
Main Circuit 194
Other Actuator Circuits 208
Travel Shock Absorbing/Travel Stop Circuit 210
Group 5 Electrical System 211
Outline 211
Main Circuit 212
Electric Power Circuit (Key Switch: OFF) 214
Electric Power Circuit (Key Switch: ACC) 216
Electric Power Circuit (Key Switch: ON) 218
Engine Starting Circuit (Engine Start Switch: ON) 230
Charging Circuit (Key Switch: ON-Engine: Running) 234
Engine Stop Circuit 236
Surge Voltage Prevention Circuit 242
Group 6 Air Conditioning System 245
Outline 245
Functions of Main Components 246
Functions of Main Electrical Parts 247
SECTION 3 COMPONENT OPERATION 253
Group 1 Pump Device 255
Outline 255
Main Pump 256
Radiator Fan Motor Pump, Oil Cooler Fan Motor Pump 258
Regulator for Main Pump 260
Regulator for Radiator Fan Motor Pump, Regulator for Oil Cooler Fan Motor Pump 268
Pump Control Solenoid Valve 288
Gear Pump 290
Pump Delivery Pressure Sensor 290
Regulator Pressure (Flow Rate Control Pressure) Sensor 290
Contamination Sensor 291
Group 2 Swing Device 293
Outline 293
Swing Motor 294
Swing Parking Brake 296
Swing Reduction Gear 297
Valve Unit 298
Group 3 Control Valve 301
Outline 301
Position of Valve and Section 302
Pilot Port Position 303
Hydraulic Circuit 304
Main Relief Valve 306
Overload Relief Valve 306
Make-Up Valve 307
Group 4 Control Equipment 309
Outline 309
Electric Control Lever 310
EDQR Valve for Electric Control Lever 314
Group 5 Travel Device 319
Outline 319
Travel Motor 320
Travel Mode Control 322
Brake Valve 326
Parking Brake 328
Travel Reduction Gear 329
Group 6 Others (Upperstructure) 331
Oil Cooler Fan Motor 331
Air Conditioner Compressor Motor, Radiator Fan Motor, Air Fan Motor, Fuel Cooler/Pump Transmission Oil Cooler Fan Motor 333
Folding Stairway Pump Unit 335
Pilot Relief Valve 336
Fan Valve 337
Solenoid Valve 343
Reducing Valve for Travel Mode Control 344
Accumulator 345
Group 7 Others (Undercarriage) 347
Swing Bearing 347
Accumulator 348
Adjuster Cylinder 349
Center Joint 350
Group 8 Others (Front Attachment) 351
Make-Up Valve 351
3-Spool Solenoid Valve Unit 354
SERVICE MANUAL REVISION REQUEST FORM 357
TTKFB91-EN-00 358
INTRODUCTION 360
SYMBOL AND ABBREVIATION 362
SAFETY 364
SECTION AND GROUP CONTENTS 408
SECTION 4 OPERATIONAL PERFORMANCE TEST 410
Group 1 Introduction 412
Operational Performance Tests 412
Preparation for Performance Tests 413
Group 2 Standard 414
Operational Performance Standard Table 414
Main Pump P-Q Diagram (P1 to P8) 418
Oil Cooler Fan Motor Pump P-Q Diagram 419
Radiator Fan Motor Pump P-Q Diagram 420
Oil Cooler Fan Motor Pump/Radiator Fan Motor Pump I-Q Diagram 421
Electric Control Lever 422
Group 3 Engine Test 426
Engine Speed 426
Group 4 Machine Performance Test 428
Travel Speed 428
Track Revolution Speed 429
Mistrack Check 430
Travel Parking Leakage 431
Swing Speed 432
Swing Function Drift Check 433
Swing Motor Leakage 435
Maximum Swingable Slant Angle 437
Swing Bearing Play 439
Hydraulic Cylinder Cycle Time 441
Cylinder Drift Check 443
Control Lever Operating Force 445
Control Lever Stroke 446
Combined Operation of Boom Raise and Swing Function Check 447
Group 5 Component Test 448
Primary Pilot Pressure 448
Secondary Pilot Pressure (Solenoid Valve of EDQR Valve) 449
Secondary Pilot Pressure (EDQR Valve) 451
Main Relief Set Pressure 453
Overload Relief Pressure 459
Main Pump Flow Rate Measurement 461
Fan Motor Pump Flow Rate 465
Swing Motor Drainage 470
Travel Motor Drainage 472
SECTION 5 TROUBLESHOOTING 476
Group 1 Diagnosing Procedure 478
Introduction 478
Diagnosis Procedure 479
Electrical System Inspection 482
Precautions for Inspection and Maintenance 483
Instructions for Disconnecting Connectors 485
Fuse Inspection 487
Slow Blow Fuse Inspection 496
Battery Voltage Check 498
Alternator Check 499
Continuity Check 500
Voltage and Current Measurement 501
Check by False Signal 511
Test Wire Harness 512
Group 2 Monitor 514
Outline 514
Warning Indicator (Engine related) 521
Warning Indicator (Except Engine related) 523
Operating Procedures of Service Menu 525
Current Alarms Faults List 527
System Check 528
Automatic Snapshot 529
Monitor and manual snapshot 531
Life 551
Controller Information 552
Log Data History 553
Maintenance History 554
Various Setup 555
Language Setup 558
How To Display Setting Menu 2 559
Setting Menu 2 561
Autolube Check 562
IO Monitor 563
Initialization of Automatic snapshot Data 564
Electric Lever Adjustment Menu 565
Pump Adjustment Menu 573
Communication Terminal Information 580
Incline Angle Adjustment 581
Various Setup 582
Group 3 Cross Reference Table 590
Group 4 Component Layout 612
Main Component (Overview) 612
Main Component (Loading Shovel) 613
Electrical System (Overview) 614
Electrical System (Around Cab Bed) 615
Electrical System (In Cab) 616
Electrical System (Around Battery) 619
Electrical System (Relay Box) 620
Electrical System (Electrical Equipment Box) 621
Electrical System (Relay Layout of Electrical Equipment Box) 622
Electrical System (LED Layout of Contamination Sensor Amplifier) 623
Electrical System (Monitoring Controller Box) 624
Electrical System (Pump Compartment Controller Box) 625
Electrical System (Angle Sensor) 626
Engine 627
Air Cleaner 628
Around Radiator 629
Water Tank 630
Around Pump 631
Fuel Cooler, Pump Transmission Oil Cooler 633
Air Fan 634
Urea SCR System 635
Fuel Tank 637
Folding Stairway 638
Around Oil Cooler 641
Auto-Lubrication Device 642
Hydraulic Oil Tank 643
Control Valve 644
Pilot Panel 648
EDQR Valve 649
Fast-Filling System 650
Fast-Filling Panel 651
Swing Device 652
Center Joint 653
Undercarriage 654
Travel Device 655
Group 5 Troubleshooting for Each Code 656
Troubleshooting Procedure for Each Code 656
How To Read Fault Code List (Appendix) 660
Group 7 Air Conditioner 662
Troubleshooting 662
Structure of Air Conditioner Unit 666
Diagnosis Procedure (Air Conditioner Controller) 669
Air Conditioner Controller Fault Code List 670
Faulty cooling 671
Faulty Heating 680
Check Refrigerant Quantity Through Sight Glass 686
Work When Replacing Components of Air Conditioner 688
Recover Refrigerant 689
Refill Compressor Oil 690
Charge Air Conditioner with Refrigerant 691
Group 8 e-Service 700
Outline 700
List of Operation Data 701
Communication System 702
Group 9 Aftertreatment Device 704
Remedy at Abnormal DEF Pressure 704
Remedy at Abnormal DEF Quality 706
Clean DEF Tank 707
Remedy when Mixing Oil in DEF Tank 708
SERVICE MANUAL REVISION REQUEST FORM 712
THE ATTACHED DOCUMENT LIST 713
WKFB91-EN-00 714
INTRODUCTION 716
SYMBOL AND ABBREVIATION 718
SAFETY 720
SECTION AND GROUP CONTENTS 764
SECTION 1GENERAL 766
Group 1 Precautions for Disassembling and Assembling 768
Precautions for Work When Removing andInstalling, Disassembling and Assembling 768
Group 2 Tightening 774
Tightening Bolts and Nuts 774
Piping Joint 777
Group 3 Painting 784
Painting 784
Group 4 Bleeding Air 785
Bleeding Air from Hydraulic Oil Tank 785
Bleeding Air from Hydraulic System 787
Bleeding Air from Fuel System 791
Bleeding Air from Water Tank 792
Group 5 Releasing Pressure 793
Releasing Pressure in Hydraulic Circuit 793
Group 6 Preparation 795
Preparation before Inspection and Maintenance 795
SECTION 2MAINTENANCE STANDARD 798
Group 1 Upperstructure 800
Pump Device 800
Swing Motor 804
Oil Cooler Fan Motor 807
Group2 Undercarriage 809
Travel Motor 809
Drive Tumbler 812
Front Idler 813
Upper Roller 814
Lower Roller 815
Track 816
Group 3 Loader Front Attachment 817
Pin and Bushing 817
Point, Shroud 819
Cylinder 820
SECTION 3UPPERSTRUCTURE 822
Group 1 Cab 824
Removal and Installation of Cab 824
Dimensions of Cab Glass 835
Removal and Installation of Escape Device 841
Group 2 Cab Bed 843
Removal and Installation of Cab Bed 843
Removal and Installation of Cab Bed Blower Motor 852
Removal and Installation of Air Conditioner Unit 853
Removal and Installation of Air Conditioner Compressor Motor 857
Disassembly of Air Conditioner Compressor Motor 859
Removal and Installation of Air Conditioner Compressors 867
Removal and Installation of Air Conditioner Condensers 869
Work When Replacing Components of Air Conditioner 871
Recover Refrigerant 872
Refill Compressor Oil 873
Charge Air Conditioner with Refrigerant 874
Group 3 Counterweight 882
Removal and Installation of Counterweight 882
Group 5 Engine Unit 890
Removal and Installation of Intake Exhaust Unit 890
Removal and Installation of Engine 895
Removal and Installation of Radiator 913
Removal And Installation of Fan Motor (Radiator) 923
Removal and Installation of Fan Motor (Air Fan) 927
Removal and Installation of Oil Cooler Core 931
Removal and Installation of Oil Cooler Fan Motor 940
Structure of Oil Cooler Fan Motor 946
Removal and Installation of Cooler Core (Fuel, Pump Transmission Oil) 947
Removal and Installation of Fan Motor (Fuel Cooler/Transmission Oil Cooler) 950
Group 6 Pump Device 954
Removal and Installation of Pump Device 954
Disassembly and Assembly of Pump Transmission 988
Disassembly and Assembly of Tandem Pumps 990
Disassembly and Assembly of Regulator for Main Pump1011
Disassembly and Assembly of Regulator for Fan Motor Drive Pump1016
Structure of Gear Pump1026
Group 7 Control Valve1030
Removal and Installation of Control Valve1030
Disassembly of Control Valve1051
Assembly of Control Valve1061
Group 8 Other Valves1067
Removal and Installation of EDQR Valve1067
Structure of EDQR Valve1074
Structure of Proportional Solenoid Valve1076
Group 9 Swing Device1078
Removal and Installation of Swing Device1078
Disassembly and Assembly of Swing Device1085
Disassembly and Assembly of Swing Motor1087
Disassembly and Assembly of Valve Unit1111
Group 10 Aftertreatment Device1117
Removal and Installation of DEF Tank1117
Removal and Installation of DEF Hose1126
Group 11 Hydraulic Oil Tank1130
Removal and Installation of Hydraulic Oil Tank1130
Group 12 Fuel Tank1141
Removal and Installation of Fuel Tank1141
Group 13 Lift Cylinder (Fast-Filling System)1149
Removal and Installation of Lift Cylinder (Fast-Filling System)1149
Disassembly of Lift Cylinder (Fast-Filling System)1152
Assembly of Lift Cylinder (Fast-Filling System)1154
Group 14 Lift Cylinder (Folding Stairway)1156
Removal and Installation of Lift Cylinder (Folding Stairway)1156
Disassembly of Lift Cylinder (Folding Stairway)1160
Assembly of Lift Cylinder (Folding Stairway)1162
SECTION 4UNDERCARRIAGE1164
Group 1 Swing Bearing1166
Removal and Installation of Swing Bearing1166
Group 2 Travel Device1173
Removal and Installation of Travel Device1173
Removal and Installation of Transmission Guard (OP)1182
Disassembly and Assembly of Travel Device1188
Disassembly and Assembly of Travel Motor1189
Disassembly and Assembly of Travel Mode Selector Valve1191
Group 3 Travel Brake Valve1192
Removal and Installation of Travel Brake Valve1192
Disassembly and Assembly of Travel Brake Valve1199
Group 4 Drive Tumbler1203
Removal and Installation of Drive Tumbler1203
Group 5 Center Joint1214
Removal and Installation of Center Joint1214
Disassembly of Center Joint1228
Assembly of Center Joint1232
Group 6 Adjuster Cylinder1238
Removal and Installation of Adjuster Cylinder1238
Disassembly and Assembly of Adjuster Cylinder1242
Group 7 Front Idler1249
Removal and Installation of Front Idler1249
Disassembly and Assembly of Front Idler1250
Group 8 Upper and Lower Rollers1257
Removal and Installation of Upper Roller1257
Removal and Installation of Lower Roller1261
Disassembly and Assembly of Upper Roller1265
Disassembly and Assembly of Lower Roller1272
Group 9 Track1279
Removal and Installation of Track1279
Structure of Track1283
Group 10 Accumulator1284
Removal and Installation of Accumulator1284
Disassembly and Assembly of Accumulator1288
Assembly of Accumulator1290
Accumulator Maintenance Inspection1294
Inspection1295
Charging Nitrogen Gas1299
Group 11 Welding Repair Procedure1301
Welding Repair Procedure1301
Repair Track Shoes (Shoe Lugs)1303
Repair Rollers1307
Repair Drive Tumbler1311
SECTION 5LOADER FRONT ATTACHMENT1315
Group 1 Front Attachment1317
Removal and Installation of Bucket1317
Removal and Installation of Arm1327
Removal and Installation of Boom1346
Group 2 Cylinder1358
Removal and Installation of Boom Cylinder1358
Removal and Installation of Arm Cylinder1364
Removal and Installation of Bucket Cylinders1372
Removal and Installation of Level Cylinder1381
Removal and Installation of Dump Cylinder1389
Disassembly and Assembly of Cylinder1394
Bleeding Air Procedure1396
Group 3 Bushing1398
Removal and Installation of Bushing1398
Group 4 Angle Sensor1399
Removal and Installation of Angle Sensors1399
Group 5 Other Valves1406
Removal and Installation of 3-Spool Solenoid Valve Unit1406
Structure of 3-Spool Solenoid Valve Unit1408
Removal and Installation of Make-Up Valve1410
Disassembly of Make-Up Valve1411
Assembly of Make-Up Valve1413
SERVICE MANUAL REVISION REQUEST FORM1415
THE ATTACHED PATTERN LIST1416
Track Shoe Pattern (A)1417
Track Shoe Pattern (B)1418
Upper Roller Pattern1419
Lower Roller Pattern1420
Drive Tumbler Pattern1421
Idler Pattern1422
Point (Tooth) Patten1423
Shroud (Lip) Pattern1424

S.M 1/2/25