Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)
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Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)
- Manual Language:English
- Pages: 283
- Size: 2.48 MB
- Downloadable:Yes
- Format:PDF
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Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)
1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.
3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows:
Table Of Contents:
Hitachi EX1200-5 Technical Troubleshooting Manual (TTLA-435-EX)
MATERIALS TOP...................................................... 0 Performance Check & Troubleshooting................................ 1 SECTION 4 OPERATIONAL PERFORMANCE TEST............................. 2 CONTENTS....................................................... 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 Parking Function.................................... 11 Swing Speed................................................ 12 Swing Function Drift....................................... 13 Swing Motor Leakage........................................ 15 Maximum Swingable Slant Angle.............................. 16 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..................................... 26 Secondary Pilot Pressure................................... 28 Solenoid Valve Set Pressure................................ 29 Main Pump Delivery Pressure................................ 32 Main Relief Valve Set Pressure............................. 33 Overload Relief Valve Set Pressure......................... 37 Main Pump Flow Rate Measurement............................ 41 Oil Cooler Fan Motor Drive Pump Flow Rate Measurement...... 47 Swing Motor Drainage....................................... 53 Travel Motor Drainage...................................... 55 Group 5 Standard............................................... 58 Operational Performance Standard........................... 58 Main Pump P-Q Diagram...................................... 61 Oil Cooler Fan Motor Drive Pump P-Q Diagram................ 61 Injection Pump............................................. 62 SECTION 5 TROUBLESHOOTING.......................................... 64 CONTENTS....................................................... 64 Group 1 General................................................ 66 Introduction............................................... 66 Diagnosing Procedure....................................... 67 Built-In Diagnosing System Operation....................... 69 Built-In Diagnosing Function Display List.................. 71 Binary Number Bit List..................................... 76 Main Controller Fault Code List ........................... 79 Group 2 Component Layout....................................... 82 Main Components............................................ 82 Electrical System Components (1)........................... 83 Electrical System Components (2)........................... 84 Electrical System Components (3)........................... 85 Electrical System Components (4)........................... 86 On and Around Pumps........................................ 87 Main Control Valve......................................... 89 Swing Control Valve........................................ 93 Signal Control Valve....................................... 98 Others.....................................................107 Group 3 Troubleshooting A......................................108 Troubleshooting A Procedure................................108 Main Controller Fault Code List............................109 Main Controller A..........................................111 Fault Code 01, 02, 03......................................111 Fault Code 04..............................................111 Fault Code 05..............................................112 Fault Code 06..............................................113 Fault Code 07..............................................114 Fault Code 08, 09..........................................115 Fault Code 10..............................................117 Fault Code 11, 12, 13......................................119 Fault Code 14..............................................120 Fault Code 25..............................................121 Main Controller B..........................................122 Fault Code 31, 32, 33......................................122 Fault Code 34..............................................122 Fault Code 37..............................................123 Sensor Activating Range....................................124 Group 4 Troubleshooting B......................................126 Troubleshooting B Procedure................................126 Correlation between Trouble Symptoms and Part Failures.....127 Engine System Troubleshooting..............................139 All Actuator System Troubleshooting........................165 Front Attachment System Troubleshooting....................173 Swing System Troubleshooting...............................187 Travel System Troubleshooting..............................190 Other System Troubleshooting...............................197 Group 5 Troubleshooting C......................................212 Troubleshooting C Procedure................................212 Malfunction of Coolant Temperature Gauge...................213 Malfunction of Fuel Gauge..................................215 Malfunction of Indicator Light Check System................217 Malfunction of Overheat Indicator..........................219 Malfunction of Air Cleaner Restriction Indicator...........221 Malfunction of Fuel Level Indicator........................223 Malfunction of Preheat Indicator...........................225 Malfunction of Download Indicator..........................226 Malfunction of Alternator Indicator........................227 Malfunction of Engine Oil Pressure Indicator...............229 Malfunction of Pump Transmission Oil Pressure Indicator....231 Malfunction of Engine Exhaust Gas Temperature Indicator....233 Malfunction of Engine Oil Level Indicator..................235 Malfunction of Coolant Level Indicator.....................237 Malfunction of Hydraulic Oil Level Indicator...............239 Malfunction of Auto-Lubrication Indicator..................243 Malfunction of Engine Stop Indicator.......................245 Malfunction of Engine Warning Indicator....................247 Malfunction of Quick-Idle Indicator........................249 Malfunction of Auto-Idle Indicator.........................251 Malfunction of Hour Meter..................................253 Malfunction of Buzzer......................................255 Malfunction of LCD.........................................257 Malfunction of Engine Troubleshooting Operation............259 Group 6 Troubleshooting D......................................262 Troubleshooting D Procedures...............................262 How to Read Fault Codes on ECM Engine Diagnosis System.....263 Group 7 Electrical System Inspection...........................266 Precautions for Inspection and Maintenance.................266 Instructions for Disconnecting Connectors..................268 Fuse Inspection............................................269 Fusible Link Inspection....................................272 Battery Voltage Check......................................272 Alternator Check...........................................273 Voltage Check..............................................275 Continuity Check...........................................282
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