Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Workshop + Troubleshooting + Operational Principle + Circuit & Harness Manual
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Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Troubleshooting + Operational Principle + Circuit & Harness Manual
This Listing includes all of the manuals mentioned below:
- Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Troubleshooting Manual
- Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Operational Principle Manual
- Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Circuit Diagram & Harness Manual
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DESCRIPTION:
Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Troubleshooting + Operational Principle + Circuit & Harness Manual
- 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. 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. Precautions for Disassembling and Assembling
- Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.
- Inspect the Machine Be sure to thoroughly understand all disassembling/ assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.
- The machine model, machine serial number, and hour meter reading. Reason for disassembly (symptoms, failed parts, and causes).
- Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants.
- Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.
TABLE OF CONTENTS:
Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Operational Principle Manual
INDEX………………………………………………………………. 0
INDEX(TT)…………………………………………………………… 1
INTRODUCTION………………………………………………………… 2
SAFETY……………………………………………………………… 4
TECHNICAL MANUAL (Troubleshooting)…………………………………….. 28
SECTION 05 OPERATIONAL PERFORMANCE TEST………………………………… 30
Group 01 Introduction…………………………………………….. 32
Operational Performance Tests………………………………….. 32
Preparation for Performance Test……………………………….. 33
Group 02 Engine Test……………………………………………… 34
Engine Speed…………………………………………………. 34
Engine Compression Pressure……………………………………. 36
Valve Clearance Adjustment…………………………………….. 37
Nozzle Check…………………………………………………. 39
Injection Timing……………………………………………… 41
Group 03 Excavator Test…………………………………………… 42
Travel Speed…………………………………………………. 42
Track Revolution Speed………………………………………… 43
Mistrack Check……………………………………………….. 44
Travel Parking Function Check………………………………….. 45
Swing Speed………………………………………………….. 46
Swing Function Drift Check…………………………………….. 47
Swing Motor Leakage…………………………………………… 48
Swing Bearing Play…………………………………………… 49
Maximum Swingable Slant Angle………………………………….. 50
Hydraulic Cylinder Cylve Time………………………………….. 51
Dig Function Drift Check………………………………………. 52
Control Lever Operating Force………………………………….. 53
Control Lever Stroke………………………………………….. 54
Combined Boom Raise / Swing Function Check………………………. 55
Group 04 Component Test…………………………………………… 56
Primary Pilot Pressure………………………………………… 56
Secondary Pilot Pressure………………………………………. 58
Solenoid Valve Set Pressure……………………………………. 59
Main Pump Delivery Pressure……………………………………. 62
Main Relief Valve Set Pressure…………………………………. 63
Overliad Relief Valve Set Pressure……………………………… 67
Main Pump Flow Test…………………………………………… 69
Swing Motor Drainage………………………………………….. 73
Travel Motor Drainage…………………………………………. 75
Group 05 Standard………………………………………………… 78
Oerational Performance Standard Table…………………………… 78
Main Pump P-Q Diagram…………………………………………. 81
Injection Pump……………………………………………….. 82
SECTION 06 TROUBLESHOOTING……………………………………………. 86
Group 01 Diagnosing Procedure……………………………………… 88
Introduction…………………………………………………. 88
Diagnosing Procedure………………………………………….. 89
Dr.EX……………………………………………………….. 91
Dr.EX Start-Up Procedure………………………………………. 91
List of Fault Code……………………………………………. 92
Monitoring Function…………………………………………… 93
Group 02 Component Layout…………………………………………. 96
Main Components………………………………………………. 96
Electrical System (Overall System)……………………………… 97
Electrical System (Relays)…………………………………….. 98
Electrical System (Monitor and Switch Panels)……………………. 99
Pump and Related Part………………………………………….100
Control Valve…………………………………………………101
Other Components………………………………………………104
Group 03 Troubleshooting A…………………………………………106
Troubleshooting A Procedure…………………………………….106
List of Fault Code…………………………………………….107
Fault Code 01, 02, 03………………………………………….108
Fault Code 04…………………………………………………108
Fault Code 05…………………………………………………109
Fault Code 06…………………………………………………111
Fault Code 07…………………………………………………113
Fault Code 08, 09……………………………………………..115
Fault Code 10, 11……………………………………………..117
Fault Code 12, 13……………………………………………..119
Fault Code 14, 15, 16, 17, 18…………………………………..121
Fault Code 19…………………………………………………123
Sensor Operating Range List…………………………………….125
Group 04 Troubleshooting B…………………………………………126
Troubleshooting B Procedure…………………………………….126
Relationship Between Machine Trouble Symptoms and Parts in Trouble….127
Correlation between Trouble Symptoms and Parts Failures……………139
Engine Troubleshooting…………………………………………145
Actuator Control System Troubleshooting………………………….157
Front Attachment Control System troubleshooting…………………..165
Swing Systm Troubleshooting…………………………………….177
Travel System Troubleshooting…………………………………..180
Troubleshooting for Other Functions……………………………..185
Engine Speed Adjustment and Engine Learning………………………187
Pump Learning…………………………………………………188
Exchange Inspection Method……………………………………..189
Pump Control Line Direct Connection Method……………………….191
EC Sensor Installation and Voltage Adjustment…………………….192
A Sensor Installation and Voltage Ajustment………………………193
Group 05 Troubleshooting C…………………………………………194
Troubleshooting C Procedure…………………………………….194
Malfunction of Coolant Temperature Gauge…………………………195
Malfunction of Fuel Gauge………………………………………197
Malfunction of Indicator Light Check System………………………199
Malfunction of Level Check Switch……………………………….199
Malfunction of Engine Oil Level Indicator………………………..201
Malfunction of Coolant Level Indicator…………………………..203
Malfunction of Hydraulic Oil Level Indicator…………………….205
Malfunction of Alternator Indicator……………………………..207
Malfunction of Engine Oil Pressure Indicator……………………..209
Malfucntion of Overheat Indicator……………………………….211
Malfunction of Fuel Level Indicator……………………………..213
Malfunction of Air Filter Restriction Indicator…………………..215
Malfunction of Buzzer………………………………………….217
Malfunction of Hour Meter………………………………………219
Group 06 Electrical System Instection……………………………….220
Precautions for Inspection and Maintenance……………………….220
Inspection for Disconnecting Connectors………………………….222
Fuse Continuity Test…………………………………………..223
Inspection and Replacement of Fusible Links………………………224
Battery Voltage and Current Check……………………………….225
How to Troubleshooting Alternator Malfuctions…………………….226
Continuity Check………………………………………………227
Voltage and Current Check………………………………………229
Replacement of Relay…………………………………………..233
Group 07 Harness Check…………………………………………….234
Circuit Check…………………………………………………234
CIRCUIT DIAGRAM………………………………………………………238
Cab Harness………………………………………………………238
Engine Harness……………………………………………………239
Electrical Circuit Diagram…………………………………………240
Relay Harness…………………………………………………….241
Connectors……………………………………………………….242
Air Conditioner Harness……………………………………………243
Hitachi EX200-5(Japanese Domestic Version) Hydraulic Excavator Troubleshooting Manual
INDEX……………………………………………………… 0
INDEX(TO)………………………………………………….. 1
INTRODUCTION……………………………………………….. 2
TECHNICAL MANUAL……………………………………………. 4
SECTION 01 GENERAL………………………………………….. 6
Group 01-Specification…………………………………… 8
Specification……………………………………….. 8
Working Ranges And Machine Dimensions For Transportation…. 9
Engine……………………………………………… 10
Engine Accessories…………………………………… 13
Hydraulic Devices……………………………………. 13
Electrical Equipment…………………………………. 15
Group 02-Component Layout………………………………… 16
Main Conponents……………………………………… 16
Electrical System (Overall System)…………………….. 17
Electrical System (Relays)……………………………. 18
Electrical System (Monitor and Switch Panels)…………… 19
Pump And Related Parts……………………………….. 20
Other Components…………………………………….. 21
SECTION 02 UPPERSTRUCTURE……………………………………. 24
Group 01-Pump Device…………………………………….. 26
Outline…………………………………………….. 26
Main Pump…………………………………………… 27
Regulator…………………………………………… 30
Pilot Pump………………………………………….. 37
N Sensor (Engine Speed Sensor)………………………… 37
Pump Pressure Sensor…………………………………. 37
A Sensor (Pump Displacement Angle Sensor)………………. 38
Group 02-Swing Device……………………………………. 40
Outline…………………………………………….. 40
Swing Motor…………………………………………. 41
Brake Valve…………………………………………. 43
Swing Parking Brake………………………………….. 45
Swing Reduction Gear…………………………………. 46
Group 03-Control Valve…………………………………… 48
Outline…………………………………………….. 48
Hydraulic Circuit……………………………………. 52
Flow Combiner Valve………………………………….. 54
Pump Control Valve…………………………………… 55
Main Relief Valve……………………………………. 57
Overload Relief Valve (With Make-Up Function)…………… 58
Variable Restriction…………………………………. 59
Arm Regenerative Valve……………………………….. 59
Boom Anti-Drift Valve,Arm Anti-Drift Valve …………….. 61
Bucket Flow Control Valve…………………………….. 61
Travel Flow Control Valve…………………………….. 63
Travel / Boom Lower Selector Valve…………………….. 63
Boom Regenerative Valve………………………………. 65
Group 04-Pilot Valve…………………………………….. 66
Outline…………………………………………….. 66
Operation…………………………………………… 70
Group 05-Others…………………………………………. 76
Pilot Shut-Off valve…………………………………. 76
Shockless Valve……………………………………… 77
Solenoid Valve Unit………………………………….. 79
Pilot Relief Valve…………………………………… 81
Section 03 UNDERCARRIAGE…………………………………….. 84
Group 01-Pilot Valve…………………………………….. 86
Outline…………………………………………….. 86
Travel Reduction Gears……………………………….. 87
Travel Motor………………………………………… 88
Travel Brake Valve…………………………………… 93
Parking Brake……………………………………….. 97
Group 02-Others………………………………………….100
Swing Bearing………………………………………..100
Center Joint…………………………………………101
Track Adjuster……………………………………….102
SECTION 04 SYSTEM …………………………………………..106
Group 01-Electrical Circuit……………………………….108
Outline……………………………………………..108
Electic Power Circuit (Key Switch Off)………………….109
Preheat Circuit………………………………………111
Starting Circuit (Key Switch Start)…………………….113
Charging Circuit (Key Switch On)……………………….115
Surge Voltage Prevention Circuit……………………….119
Accessory Circuit…………………………………….121
Engine Stop Circuit…………………………………..122
Group 02-Hydraulic Circuit………………………………..124
Main Circuit…………………………………………124
Pilot Circuit………………………………………..125
Neutral Circuit ……………………………………..126
Single Actuator Operation……………………………..126
Combined Operation……………………………………127
Group 03-Control System…………………………………..130
Outline……………………………………………..130
Engine Control ………………………………………131
Pump Control ………………………………………..138
Valve Control ……………………………………….146
Other Control Function………………………………..152
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