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
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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
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