Factory Workshop Manual and Technical Manual For Hitachi EX550-5, EX600H-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
Pages: 585
Bookmarks: No
Searchable: No
Number:
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi EX550-5, EX600H-5
Contents
Workshop Manual
- -GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Maintenance Standard
Terminology
–TIGHTENING
Tightening Torque Specification
Torque Chart
Piping Joint - -UPPERSTRUCTURE
–CAB
Remove and Install Cab
Dimensions of the Cab Glass
–COUNTERWEIGHT
Remove and Install Counterweight
–PUMP DEVICE
Remove and Install Pump Device
Disassemble Pump Transmission
Assemble Pump Transmission
Remove and Install Main Pump
Disassemble Main Pump
Assemble Main Pump
Disassemble and Assemble Pilot Pump
–CONTROL VALVE
Remove and Install Control Valve
Disassemble Control Valve 1
Assemble Control Valve 1
Disassemble Control Valve 2
Assemble Control Valve 2
Disassemble Control Valve 3
Assemble Control Valve 3
Disassemble Control Valve 4
Assemble Control Valve 4
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
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install Left Pilot Valve
Remove and Install Travel Pilot Vatve
Disassemble Front Attachment Pilot Valve
Assemble Front Attachment Pilot Valve
Disassemble Travel Pilot Valve
Assemble Travel Pilot Valve
–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 Front Attachment Shockless Valve
Disassemble and Assemble Front Attachment Shockless Valve
Remove and Install Travel Shockless Valve
Disassemble and Assemble Travel Shockless Vatve
–SOLENOID VALVE
Remove and Install
Three-Spool Solenoid Valve
Disassemble and Assemble Three-Spool Solenoid 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
Assemble Upper Roller
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
–TRACK
Remove and Install Tracks
Maintenance Standard - -FRONT ATTACHMENT
–FRONT ATTACHMENT
Preparation for Removing and Installing Cylinder
Remove and Install Cylinder
Maintenance Standards
Air Bleeding Procedure
–CYLINDER
Disassemble Cylinders
Assemble Cylinders
Maintenance Standards
Technical Manual
- SAFETY
- -GENERAL
–SPECIFICATION
Specifications
Working Ranges I Transporting
Dimensions
–COMPONENT LAYOUT
Mam Components
Electrical System (1)
Electrical System (2)
Electrical System (3)
Control Valve
Others - -SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Valve Control
Other Control
–HYDRAULIC SYSTEM
Outline
Main Circuit
Pilot Circuit
–ELECTRICAL SYSTEM
Outline
Power Circuit
Bulb Check Circuit
Engine Start Circuit
Charging Circuit
Accessory Circuit
Surge Voltage Prevention Cirouit
Engine Stop Circuit - -COMPONENT OPERATION
–PUMP DEVICE
Outline
Main Pump
Regulator
Pilot Pump
N Sensor (Engine Speed Sensor)
P Sensor (Pump Delivery Pressure Sensor)
A Sensor (Pump Displacement Angle 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
Maili Relief Vdlve
Overload Relief Valve
Make-Up Valve
Holding Valve
Arm Regenerative Valve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Reduction Gear
Travel Motor
Travel Brake Valve
Travel Motor Displacement
Angle Shift
Parking Brake
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Shockless Valve
Solenoid Valve Unit
Accumulator
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster - -OPERATIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Tests
Preparation for Performance
Test
–ENGINE TEST
Engine Speed
Injector and Valve Clearance Adjustment
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Function Check
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Boom Raise/Swing Combined Operation Check
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Main Relief Pressure Shift Control Pressure(SA Pressure)
Travel Mode Shift Control Pressure(SB Pressure)
Swing Parking Brake Release Pressure(SC Pressure)
Main Relief Pressure
Overload Relief Pressure
Main Pump Flow Rate
Swing Motor Drainage
Travel Motor Drainage
–STANDARD
Operational Performance Standard Table - -TROUBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
Dr EX
Dr EX Start-Up Procedure
Clearing the Self-Diagnosing
Retrial “A”
Retrial “B”
EC Related Fault Codes
PVC Related Fault Codes
Monitoring Function
–COMPONENT LAYOUT
Main Components
Electrical System (1)
Electrical System (2)
Electrical System (3)
Control Valve
Others
–TROUBLESHOOTING A
Tiuublehliuuliny A Piuceduie
EC Related Fault Codes
PVC Related Fault Codes
Fault Codes 0102 03,04,06 (Failure (type 1,2, 3,4,6) of EC]
Fault Code 05 (Signal from PVC is not Transmitted to EC)
Fault Codes 09,10 (Short Circuit and Discontinuity of EC Sensor)
Fault Codes 11, 12 (Short Circuit and Discontinuity of Eng Governor Dial/Lever Angle Sensor)
Fault Code 13 (N Sensor Malfunction)
Fault Code 14 (Discontinuty of overheat Switch L and/or Hydraulic oil Temperature Sensor)
Fault Codes 17, 18 19 21,22 (Failure (type 17, 18, 19 21,22) of PVC]
Fault Code 20 (Signal from EC is not Transmitted to PVC)
Fault Codes 23 24 (Pump Control Malfunction)
Fault Codes 26 34 (Discontinuity of DP Sensor)
Fault Codes 27, 28, 35, 36 (Short Circuit and Discontinuty of P Sensor)
Fault Codes 29, 30 37, 38 (Short Circuit and Discontinuity of A Sensor)
Sensor Operating Range List
–TROUBLESHOOTING B
Troubleshooting B Procedure
Correlation between Part Failure and
Abnormalities that Machine may Show Correlation between Troubles and Part Failures
Engine System Troubleshooting
Total Actuator System Troubleshooting
Front Attachment System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Troubleshooting for Other Functions
EC Sensor Installation and Voltage Adjustment
Installation and Adjustment of the A Sensor
–TROUBLESHOOTING C
Troubleshooting C Procedure
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Indicator Bulb Check System
Malfunction of Level Check Switch
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 Fitter Restriction Indicator
Malfunction of Hour Meter
Malfunction of Buzzer
Malfunction of Work Light Indicator
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Continuity Test
Fusible Link Inspection and Replacement
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Check
Check Using False Signal
Relay Replacing Procedure
–HARNESS CHECK
Circuit Check
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