Hitachi EX12 To EX42-2 Workshop Manual manuals in PDF

Factory Technical and Workshop Manuals For Hitachi EX12 To EX42-2 Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 868
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Hitachi EX12-2, EX15-2, EX18-2, EX22-2, EX25-2, EXЗ0-2, EX35-2, EX40-2, EX45-2

Contents

1.Technical Manual

INTRODUCTION
-GENERAL
–SPECIFICATION
Specifications
Working Range Transportation
Engine Specification
Interchangeability
–COMPONENT LAYOUT
Main Components
Electrical System (Overall System)
Electrical System (Relays)
Electrical System (Monitor and Switches)
-SYSTEM
–HYDRAULIC SYSTEM
Outline
Main Circuit
Pilot Circuit
-COMPONENT OPERATION
–PUMP DEVICE
Outline
Main Pump
Pilot Pump
–SWING DEVICE
Outline
Swing Motor
Parking Brake Changeover Valve
Valve Unit
Swing Reduction Gear
–CONTROL VALVE
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Valve
Overload Relief Valve
Make-up Valve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Motor
Travel Brake Valve
Travel Reduction Gear
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Solenoid Valve
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
-OPERATIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Test
Preparation for Performance Tests
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance
Nozzle Check
Injection Timing
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Motor Leakage
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift
Control Lever Operating Force
Control Lever and Pedal Stroke
Combined Boom Raise/Swing Function Check
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Main Relief Valve Set Pressure
Overload Relief Valve Set Pressure
Swing Motor Relief Valve Set Pressure
Swing Motor Drainage
Travel Motor Drainage
–STANDARD
Operational Performance Standard
-TROUBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
–TROUBLESHOOTING A
Troubleshooting A Procedure
Engine system Troubleshooting
Actuator Operating System Troubleshooting
Front Attachment System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Blade System Troubleshooting
–TROUBLESHOOTING B
Troubleshooting B Procedure
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Alternator Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Overheat Indicator
Malfunction of Fuel Level Indicator
Malfunction of Air Filter Restriction Indicator
Malfunction of Buzzer
Malfunction of Hour Meter
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Fuse Continuity Test
Battery Voltage Check
Voltage Check
Continuity Check
-ATTACHED DIAGRAM LIST
EX12-2 EX15-2 EX18-2 Electrical Circuit (Tуpe A)
EX12-2 EX15-2 EX18-2 Electrical Circuit (Type B)
EX22-2 EX25-2 EX30-2 EX35-2 EX40-2 EX45-2 Electrical Circuit (Tуpe A)
EX22-2 EX25-2 EX30-2 EX35-2 EX40-2 EX45-2 Electrical Circuit (Tуpe B)

2.Workshop Manual

INTRODUCTION
SAFETY
-GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
–TIGHTENING
Tightening Torque Specifications
Torque Chart
Piping Joint
-UPPERSTRUCTURE
–CANOPY
Remove and Install Canopy
–COUNTERWEIGHT
Remove and Install Counterweight
–PUMP DEVICE
Remove and Install Pump Device
Disassemble and Assemble Pump Device
Maintenance Standard
–CONTROL VALVE
Remove and Install Control Valve
Disassemble and Assemble Control Valve
–SWING DEVICE
Remove and Install Swing Device
Disassemble and Assemble Swing Reduction Gear
Disassemble and Assemble Swing Motor
Maintenance Standard
–PILOT VALVE
Remove and Install Pilot Valve
Disassemble and Assemble Pilot Valve
–SOLENOID VALVE
Disassemble and Assemble Travel Speed Change Solenoid Valve
-UNDERCARRIAGE
–SWLNG BEARING
Remove and Install Swing Bearing
–TRAVEL DEVICE
Remove and Install Travel Device
Disassemble and Assemble Travel Device
Maintenance Standards
–CENTER JOINT
Remove and Install Center Joint
Disassemble and Assemble Center Joint
–TRACK ADJUSTER
Remove and Install Track Adjuster
–FRONT IDLER
Remove and Install Front Idler
Maintenance Standards
–UPPER AND LOWER ROLLERS
Remove and Install Upper Roller
Remove and Install Lower Roller
Maintenance Standards
–TRACK
Remove and Install Rubber Track
Maintenance Standards
-FRONT ATTACHMENT
–FRONT ATTACHMENT
Remove and Install Front Attachment
Maintenance Standards
–CYLINDERS
Remove and Install Cylinders
Disassemble and Assemble Cylinders
-ENGINE-EX12-2, EX15-2, EX18-2, EX22-2, EX25-2, EX30-2, EX35-2
SPECIFICATIONS
PERFORMANCE CURVES
DIMENSIONS
–MECHANISM
FEATURE
Engine Body
Cylinder Block
Cylinder Head
Crankshaft
Piston And Piston Rings
Connecting Rod
Camshaft
Flywheel
Rocker Arm
LUBRICATING SYSTEM
General
Oil Pump
Relief Valve
Oil Filter Cartridge
Oil Pressure Switch
COOLING SYSTEM
General
Waterpump
Thermostat
Radiator
Radiator Cap
INTAKE/EXHAUST SYSTEM
Air Cleaner
Muffler
FUEL SYSTEM
General
Injection Pump
Injection Nozzle
Fuel Filter
Governor
Automatic Advance Timer
ELECTRICAL SYSTEM
Charging System
–DISASSEMBLING AND SERVICING
GENERAL
Engine Identification
General Precautions
Tightening Torques
Troubleshooting
Servicing Specifications
Maintenance Check List
Check And Maintenance
Special Tools
ENGINE BODY
Checking And Adjusting
Disassembling And Assembling
Draining Water And Oil
External Components
Cylinder Head And Valves
Gear Case
Piston And Connecting Rod
Flywheel And Crankshaft
Servicing
Cylinder Head
Timing Gear And Camshaft
Piston And Connecting Rod
Crankshaft
Cylinder Liner
LUBRICATING SYSTEM
Checking
Servicing
Oil Pump
COOLING SYSTEM
Checking
Fan Belt
Radiator
Disassembling And Assembling
FUEL SYSTEM
Checking And Adjusting
Injection Pump
Injection Nozzle
Disassembling And Assembling
Injection Pump
Injection Nozzle
ELECTRICAL SYSTEM
Checking
Starter
Glowplug
Disassembling And Assembling
Starter
Alternator
Servicing
Starter
Alternator
-ENGINE-EX40-2, EX45-2
SAFETY INSTRUCTIONS
SPECIFICATIONS
PERFORMANCE CURVES
DIMENSIONS
–MECHANISM
FEATURE
Engine Body
Cylinder Block
Cylinder Head
Crankshaft
Piston And Piston Rings
Connecting Rod
Camshaft
Flywheel
Rocker Arm
LUBRICATING SYSTEM
General
Oil Pump
Relief Valve
Oil Filter Cartridge
Oil Pressure Switch
COOLING SYSTEM
General
Waterpump
Thermostat
Radiator
Radiator Cap
INTAKE/EXHAUST SYSTEM
Air Cleaner
Muffler
FUEL SYSTEM
General
Injection Pump
Injection Nozzle
Fuel Filter
Fuel Lift Pump
Governor
ELECTRICAL SYSTEM
Charging System
–DISASSEMBLING AND SERVICING
GENERAL
Engine Identification
General Precautions
Tightening Torques
Troubleshooting
Servicing Specifications
Maintenance Check List
Check And Maintenance
Special Tools
ENGINE BODY
Checking And Adjusting
Disassembling And Assembling
Draining Water And Oil
External Compornents
Cylinder Head And Valves
Gear Case
Piston And Connecting Rod
Flywheel And Crankshaft
Servicing
Cylinder Head
Timing Gear And Camshaft
Piston And Connecting Rod
Crankshaft
Cylinder Bore
LUBRICATING SYSTEM
Checking
Servicing
Oil Pump
COOLING SYSTEM
Checking
Fan Belt
Radiator
Disassembling And Assembling
FUEL SYSTEM
Checking And Adjusting
Injection Pump
Injection Nozzle
Disassembling And Assembling
Injection Pump
Injection Nozzle
ELECTRICAL SYSTEM
Checking
Starter
Glowplug
Alternator And Regulator
Disassembling And Assembling
Starter
Alternator
Servicing
Starter
Alternator

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