Factory Technical Manual and Workshop Manual For Hitachi EX200-5 EX200LC-5 EX220-5 EX220LC-5 EX230LC-5 EX270-5 EX270LC-5 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
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi EX200-5, EX200LC-5, EX220-5, EX220LC-, EX230LC-5, EX270-5, EX270LC-5
Contents
1.Technical Manual
-GENRAL
–SPECIFICATION
Specifications
Working Ranges and Machine Dimensions for Transportation
–COMPONENT LAYOUT
How to See Component Layout Pages
Main Components
Electrical System (Overall System)
Electrical System (Relays)
Electrical System (Monitor and Switch Panels)
Pump and Related Parts
Other Components
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Valve Control
Other Control Function
–HYDRAULIC SYSTEM
Main Circuit
Pilot Circuit
Neutral Circuit
Single Actuator Operation
Combined Operation
–ELECTRICAL SYSTEM
Outline
Electric Power Circuit
Bulb Check Circuit
Preheat Circuit
Starting Circuit
Charging Circuit
Surge Voltage Prevention Circuit
Accessory Circuit
Engine Stop Circuit
-COMPONENT OPERATION
–PUMP DEVICE
Outline
Main Pump
Regulator
Pilot Pump
N Sensor (Engine Speed Sensor)
Pump Pressure Sensor
–SWING DEVICE
Outline
Swing Motor
Valve Unit
Swing Parking Brake
Swing Reduction Gear
–CONTROL VALVE
Outline
Hydraulic Circuit
Flow Combiner Valve
Pump Control Valve
Main Relief Valve
Overload Relief Valve
(With Make-Up Function)
Arm Regenerative Valve
Boom Anti-Drift Valve, Arm Anti-Drift Valve
Bucket Flow Control Valve
Travel Flow Control Valve
Travel / Boom Lower Selector Valve
Boom Regenerative Valve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Reduction Gear
Travel Motor
Travel Brake Valve
Parking Brake
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Shockless Valve
Solenoid Valve Unit
Pilot Relief Valve
EC Motor
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
-ORETIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Tests
Preparation for Performance Tests
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance Adjustment
Nozzle Check
Injection Timing
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Function Check
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Swing Bearing Play
Maximum Swingable Slant Angle
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Boom Raise/Swing Function Check
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Valve Set Pressure
Overload Relief Valve Set Pressure
Main Pump Flow Test
Swing Motor Drainage
Travel Motor Drainage
–STANDARD
Operational Performance Standard Table(EX200-5, 200LC-5)
Operational Performance Standard Table(EX220-5, 220LC-5, 230LC-5)
Operational Performance Standard Table(EX270-5, 270LC-5)
Main Pump P-Q Diagram
Injection Pump
-TROUBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
DrEX
DrEX Start-Up Procedure
DrEX Fault Code
DrEX Monitoring Function
DrEX Special Function (Service Mode)
Adjustable Data List
–COMPONENT LAYOUT
How to See Component Layout Pages
Main Components
Electrical System (Overall System)
Electrical System (Relays)
Electrical System (Monitor and Switch Panels)
Pump and Related Parts
Control Valve
Others Components
–TROUBLESHOOTING A
Troubleshooting A Procedure
List of Fault Code
Fault Code 01
Fault Code 02, 03
Fault Code 04, 05
Fault Code 06
Fault Code 07
Sensor Operating Range List
–TROUBLESHOOTING B
Troubleshooting B Procedure
Relationship between Machine Trouble Symptoms and Parts in Trouble
Correlation between Trouble Symptoms and Part Failures
Engine Troubleshooting
Actuator Control System Troubleshooting
Front Attachment Control System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Troubleshooting for Other Functions
Engine Speed Adjustment and Engine Learning
Exchange Inspection Method
–Troubleshooting C
Troubleshooting C ProcedureT5-5-1 Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Indicator Light Check System
Malfunction of Level Check Switch
Malfunction of Preheat Indicator
Malfunction of Engine Oil Level Indicator
Malfunction of Coolant Level Indicator
Malfunction of Hydraulic Oil Level Indicator
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
Instructions for Disconnecting Connectors
Fuse Continuity Test
Inspection and Replacement of Fusible Links
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Check
Replacement of Relay
–HARNESS CHECK
Circuit Check
2.Workshop Manual
INTRODUCTION
SAFETY
-GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
–TIGHTENING TORQUE
Tightening Torque Specification
Torque Chart
Piping Joint
-UPPERSTRUCTURE
–CAB
Remove and Install Cab
Dimensions of the Cab Glass
–COUNTERWEIGHT
Remove and Install Counterweight
–MAIN FRAME
Remove and Install Main Frame
–PUMP DEVICE
Remove and Install
Pump Device
Disassemble Pump Device
Assemble Pump Device
Disassemble Regulator
Assemble Regulator
Disassemble and Assemble Pilot Pump
Maintenance Standard
–CONTROL VALVE
Remove and Install Control Valve
Disassemble Control Valve 1
Assemble Control Valve 1-1
Assemble Control Valve 1-2
Disassemble Control Valve 2
Assemble Control Valve 2-1
Assemble Control Valve 2-2
Disassemble Control Valve 3
Assemble Control Valve 3-1
Assemble Control Valve 3-2
Disassemble Control Valve 4
Assemble Control Valve 4-1
Assemble Control Valve 4-2
Disassemble Control Valve 5
Assemble Control Valve 5
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Device
Assemble Swing Device
Disassemble Swing Motor
Assemble Swing Motor
Disassemble and Assemble Parking Brake Release Valve (EX270-5, 270LC-5)
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install Left Pilot Valve
Remove and Install Travel Pilot Valve
Disassemble Right and Left Pilot Valve
Assemble Right and Left Pilot Valve
Disassemble Travel Pilot Valve (EX200-5, 200LC-5: Up To Serial Number 83346)
Assemble Travel Pilot Valve (EX200-5, 200LC-5: Up To Serial Number 83346)
Disassemble Travel Pilot Valve (EX200-5, 200LC-5: Serial Number 83347 and Later, 220-5, 220LC-5, 230LC-5, 270-5, 270LC-5)
Assemble Travel Pilot Valve (EX200-5, 200LC-5: Serial Number 83347 and Later, 220-5, 220LC-5, 230LC-5, 270-5, 270LC-5)
–PILOT SHUT-OFF VALVE
Remove and Install
Pilot Shut-off Valve
Disassemble Pilot Shut-off Valve
Assemble Pilot Shut-off Valve
–SHOCKLESS VALVE
Remove and Install Shockless Valve
Disassemble and Assemble Shockless Valve
–SOLENOID VALVE
Remove and Install Solenoid Valve Unit
Disassemble Propotional Solenoid Valve
Assemble Propotional Solenoid Valve
Group 11 Pilot Relief Valve Unit
Remove and Install Pilot Relief Valve Unit
Disassemble Pilot Relief Valve
Assemble Pilot Relief Valve
-UNDERCARRIAGE
–SWING BEARING
Remove and Install Swing Bearing
Disassemble Swing Bearing
Assemble Swing Bearing
–TRAVEL DEVICE
Remove and Install Travel Device
Disassemble Travel Device
Assemble Travel Device
Disassemble Travel Motor
Assemble Travel Motor
Disassemble Brake Valve
Assemble Brake Valve
Maintenance Standard
–CENTER JOINT
Remove and Install Center Joint
Disassemble Center Joint
Assemble Center Joint
Maintenance Standard
–TRACK ADJUSTER
Remove and Install Track Adjuster
Disassemble Track Adjuster
Assemble Track Adjuster
–FRONT IDLER
Remove and Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Maintenance Standard
–UPPER AND LOWER ROLLER
Remove and Install Upper Roller
Remove and Install Lower Roller
Disassemble Upper Roller (EX270-5, 270LC-5)
Assemble Upper Roller (EX270-5, 270LC-5)
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
–TRACK
Remove and Install Track
Maintenance Standard
-FRONT ATTACHMENT
–FRONT ATTACHMENT
Remove and Install Front Attachment
Maintenance Standard
Standard Dimensions for Arm and Bucket Connection
–CYLINDER
Remove and Install Cylinder
Hydraulic Circuit Pressure Release Procedure
Disassemble Cylinder (EX200-5, 200LC-5)
Assemble Cylinder (EX200-5, 200LC-5)
Disassemble Cylinder (EX220-5, 220LC-5, 230LC-5)
Assemble Cylinder (EX220-5, 220LC-5, 230LC-5)
Disassemble Cylinder (EX270-5, 270LC-5)
Assemble Cylinder (EX270-5, 270LC-5)
Maintenance Standard
-ENGINE AND ACCESSORY (EX200-5, 200LC-5)
–GENERAL INTRODUCTION
General Repair Instructions
Notes on the Format of This Manual
Main Data and Specifications
Performance Curve
External View
Tightening Torque Specifications
Angular Nut and Bolt Tightening Method
Major Parts Fixing Nuts and Bolts
Identifications
–MAINTENANCE
Lubricating System
Fuel System
Cooling System
Valve Clearance Adjustment
Injection Timing
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
–ENGINE ASSEMBLY 1 (DISASSEMBLY)
External Parts Disassembly Steps
Major Components
Rocker Arm and Rocker Arm Shaft Disassembly Steps
Cylinder Head Disassembly Steps
Piston and Connecting Rod Disassembly Steps
–LUBRICATING SYSTEM
General Description
Oil Pump
Oil Cooler
–COOLING SYSTEM
General Description
Water Pump
Thermostat
–FUEL SISTEM
General Description
Injection Nozzle
Injection Pump Calibration
–TURBOCHARGER
General Description
Turbocharger Identification
Inspection and Repairs
–AIR COMPRESSOR
General Description
Disassembly Steps
Inspection and Repairs
Reassembly Steps
–ENGINE ELECTRIALS
Starter Motor Identification
Starter Main Data and Specifications
Starter Motor Sectional View
Starter Motor Exploded View
Alternator Identifications
Alternator Sectional View
Alternator Exploded View
–TROUBLESHOOTING
—HARD STARTING
STARTER INOPERATIVE
STARTER OPERATES BUT ENGINE DOES NOT TURN OVER
3ENGINE TURNS OVER BUT DOES NOT START HOUGH FUEL IS BEARING DELIVERED TO THE INJECTION PUMP
ENGINE TURNS OVER BUT DOES NOT START
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
Warkish Exhaust Smoke
Darkish Exhaust Smoke
Oil Pressure does not Rise
Abnormal Engine Noise
–SPECIAL TOOL LIST
Special Tool List
–CONVERSION TABLE
Length
Area
Volume
Mass
Pressure
Torque
Temperature
-ENGINE AND ACCESSORY-EX220-5, 220LC-5, 230LC-5, 270-5, 270LC-5)
–GENERAL INTRODUCTION
General Precautions
How to Use this Workshop Manual
Identification Information
Specifications
Standard Tightening Torque
Recommended Lubricants
–ENGINE
Data and Specifications
Troubleshooting
Engine Overhaul Criteria
Engine Moving Parts
Lubricating System
Fuel System
Cooling System
Air Intake and Exhaust System
Engine Component Parts Dismounting and Mounting
Engine Tune-Up
Procedure for Installing Joints and Gaskets of Engine Pipes
Liquid Gasket and Application Points
–ELECTRICAL EQUIPMENT
Data and Specifications
Location of Electrical Equipment
Troubleshooting
General Instruction
Battery
Engine Starting Circuit
Intake Air Heater Circuit
Engine Stop Circuit
Meter and Gauge Circuit
–TURBOCHARGER
Data and Specifications
Troubleshooting
Overhaul Criteria
Turbocharger
–FUEL INJECTION PUMP
Description
Troubleshooting
Special Tools
Injection Pump
A, AD-Type Pump
Timer SA-Type Timer
Feed Pump FP/KE-Type Feed Pump
Adjustment
–INJECTION PUMP GOVERNOR
Description
Special Tool
Governor
–GENERATOR (24 V, 20 AI 30 A)
Data and Specifications
Descriptions
Troubleshooting
Overhaul
–GENERATOR (24 V, 40 A / 45 A)
Data and Specifications
Descriptions
Troubleshooting
Overhaul
–STARTER (24 V, 55 KW)
Data and Specifications
Description
Troubleshootings
Overhaul
–STARTER (24 V, 45 KW)
Data and Specifications
Description
Troubleshootings
Overhaul
–AIR COMPRESSOR
Data and Specifications Description
Troubleshootings
Special Tools
Overhaul
–CALIBRATION
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