Hitachi EX120-2 Technical Manual Excavator

Factory technical manual and performance check and troubleshooting manual For Hitachi EX120-2 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: 451
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Hitachi EX120-2

Contents

INTRODUCTION
SAFETY
-SPECIFICATIONS
–GENERAL INFORMATION
Foreword
Specifications
Working Range
Lifting Capacities
Service Refill Capacities
–DIMENSIONS AND WEIGHTS
Transportation
Weights
–FUELS AND LUBRICANTS
Fuel
Grease
Engine Oil
Gear Oil
Hydraulic Oil
Engine Coolant
–INTERCHANGEABILITY
Interchangeability
Installation of Attachments
-UPPERSTRUCTURE
–LAYOUT
Layout of Upperstructure
–TANKS
Construction and Function
Hydraulic Oil Tank
Fuel Tank
–PUMP DEVICE
Construction and Function
Main Pump
Regulator
Gear Pump
–SWING DEVICES
Construction and Function
Swing Motor
Brake Valve
Parking Brake
Swing Dampener Valve
Swing Reduction Device
–PIPINGS
Construction and Function
Main pipings
Pilot pipings
–CONTROL VALVE
Construction
No 1 Valve (Three spools side) No2 Valve (Four spools side)
System Pressure Regulator
Surge Relief Valve
Overload Relief Valve with Anti-Cavitation Feature
Variable Pressure Compensated
Valve
Shuttle Valve
Holding Valve
OperationfLever in Neutral)
Operation(Single)
Operation(Combined)
Hydraulic Pilot Warm Up Circuit
Auxiliary Spool Speed Adjustment
–PILOT VALVE
Construction and Function
Pilot Valve
Shuttle Valve
–LOCK VALVE
Construction and Function
–SHOCKLESS VALVE
Construction and Function
–ACCUMULATOR
Construction
Function
Cautions for Handling
–SOLENOID VALVE
Construction and Function
Solenoid Valve
Solenoid Valve Assembly
–COMPONENT LOCATION
Component Location
–SWING BEARING
Construction and Operation
–CENTER JOINT
Construction and Operation
–TRAVEL DEVICE
Construction and Operation
Travel Reduction Device
Travel Motor
Travel Brake Valve
Parking Brake
–ADJUSTER
Construction and Operation
-ELECTRICAL SYSTEM
–COMPONENT LOCATION
Component Location
Monitor and Switch Panel
Monitor Panel
Switch Panel (1)
Switch Panel (2)
Relays
Electric Wiring Diagram
Connector
Engine Harness
Cab Harness
–ENGINE CONTROL SYSTEM
Outline of the Control System Summary of Control Circuits
Outline of the Engine Control System
Operation of the Engine Control Motor
Engine Control Circuit
Setting Engine Mode Speeds and Engine Speed Programing
Engine Stop Double Function
Function of the Main Electrical Equipment
–MONITOR
Outline of the Monitor
Monitor Panel
Monitor Function
Monitor Check Procedure
–CIRCUIT OPERATION
Characteristics of the Electrical System
Power Circuit
Preheat Circuit
Engine Start Circuit
Charging Circuit
Operation of the Regulator
Voltage Adjustment
How to Troubleshoot Malfunction in the Charging Circuit
Surge Voltage Prevention Circuit
Accessory Circuit
EC Motor Engine Stop
Slop Motor Engine Stop
Key Switch Engine Stop
Emergency Engine Stop
Auto Idle Function
–INSPECTION AND MAINTENANCE
Precautions for Inspection and Maintenance
Fuse Continuity Test
Taking Apart Connector
Inspection and Replacement of Fusible Link
Installation and Adjustment of the A – Sensor
Positioning the EC Sensor
-HYDRAULIC SYSTEM
–GENERAL
General
Main Circuit
Suction Circuit
Delivery Circuit
Return Circuit
Drain CircuitT
Systerm Pressure Regulate Control
Pilot Circuit
Suction Circuit
Delivery Circuit
Return Circuit
Control System
Control Systern Layout
–CONTROL SYSTEM
Pump Control System
Load Sensing System
Speed Sensing System
Valve Control System
Flow Dividing Control System
Job Mode Selector
Propel Speed Control System
3-Speed Propel Control
Ollier Control System
Swing Parking Brake
Warming-Up Control
–MAIN HYDRAULIC CIRCUIT
Neutral Circuit
Swing Operation
Arm In Circuit
Swing Circuit
Combined Operation
Combined Boom and Swing Circuit
Relief Circuit
-OPERATIONAL PERFORMANCE TEST
–STANDARD
Operational Performance Standard
–INTRODUCTION
Purpose
Terminology
Preparation For Performance Tests
–ENGINE TEST
Engine Speed
Engine Compression Pressure
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack
Travel Parking Function Check
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Boom Raise1 Arm Roll-In Functions Check
Combined Boom RaiseSwing Functions Check
Combined Boom Raise/Arm Roll-Out /Swing Functions Check
–HYDRAULIC COMPONENT TEST
Pilot Primary Pressure
Adjustment
Pilot Secondary Pressure
Proportional Solenoid Valve Pressure ( PC Pressure)
Adjustment
Swing Parking Brake Releasing Pressure
Reducing Valve Pressure Setting (PI Pressure)
Adjustment
Main Pump Delivere Pressure
System Pressure Regulator
Relief Setting
Adjustment
Overload Relief Valve
Pressure Setting
Adjustment
Main Pump Row Test
(Reference) Pump PQ Curve
Swing Motor Drainage
Travel Motor Drainage
–BASIC PERFORMANCE CHECK
Basic Performance Check
With the Dr EX
Pressure (P) switch
In the Neutral Position, and at Relief Pressure
A sensor (Pump Displacement Angle Sensor)
Single Operation
Combined Operation
Combmed Boom raise and Arm roll-in
Combined Bucket roll-in relief and Boom raise
Combinod Bucket roll-in and Boom raise
Combined Travel and Arm roll-in relief
Swing Check with Precision mode (M4)
-TROUBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
Operation Procedure of DrEX
Self-diagnosis Function
Clearing self-diagnosis function
DrFX Monitor Function
Chock Battery Voltage and Fuses
Check Fusible Link
–CONNECTOR
Connector Location
Types of Each Connector
–TROUBLESHOOTING A
List of EC Relating Fault Codes List of PVC Relating Fault Codes
Fault Codes 01,020304 and 06
Fault Code 05
Fault Codes 09 and 10
Fault Code 13
Fault Codes 171819 and 21
Fault Code 20
Fault Codes 22
Fault Codes 25 and 26
Fault Codes 27 and 28
Fault Codes 29 and 30
Fault Codes 31 and 32
–TROUBLESHOOTING B
Outline
Effect of Electronic Component Malfunctions on Machine Operations
Machine Malfunctions and Possible Causes
ENGINE
E-1 Starter does not Rotate
E-2 Starter Rotates but Engine does not Fire
E-3 Hard to Start when Temperature is low
E-4 Engine Stalls when I ighl Load is Applied
E-5 Engine Stalls within about 10 Second After Engine Start
E-678 Auto-kile does not Function
E-91011 Abnormal Engine Speed
E-12 Engine does not Stop
ACTUATORS
A-1 Cylinder and Monitor Speed are Slow
A-2 Cylinder and Monitor do not Move
A-3 Cylinder and Monitor do not Stop Working
A -4 Poor Combined Operation
Front Attachments
F-1 Cylinder Speeds are Slow (Motor Speed are Normal)
F-2 Cylinder Moves Slowly or Docs Not Move
F-3 Front Attachment Drops Noticably
F-4 Front Attachment Drops Briefly then Begins to Move when Operating the Lever
Swing
S-1 Slow Speed or Weak Power in Swing Operation
S-3 Big Shock is Fell when Swing is Slopped
S-2 Swing Coasts Excessively when Swing Lever is Returned to Neutral
S-4 Swing Drifts Excessively on a Slope
S-5 Superstructure does not Swing
Travel
T-1 Travel Speed is Slower than Specified Ranges
T-2 Travel Speed does not Change
T-3 The Excavator Mistracks
T-4 Travel Motor do not Rotate
T-5 Travel Power is Weak
Others
0-1 Work Mode Selector Switch docs not Operate
0-2 Slow Response in Operation Control
0-3 Excessive Noise and/or Vibration from the Pump
0-4 Wiper does not Function
0-5 Fuse Fails
–TROUBLESHOOING C
Monitor Panel, Switch and Sensor Location
Malfunction of Coolant
Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Level Check Switch
Malfunction of Engine Oil Level Indicator
Malfunction ol 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 Tilter Restriction Indicator
Malfunction of Buzzer
Malfunction of Hour Meter
–HARNESS CHECK
Wiring Harness Test
lest 1 Battery Circuit Test
Test 2 5 Volt Sensor Circuit Test Test 3 Branchless Harness Test
Test 4 Test Harnesses Between Switch Panel 2 and PVC EC
Test 5 T sensor Harness lest
Test 6 Pressure Switch Harness Test
Test 7 Proportional solenoid Valve Hamess Test
Test 8 Pump Displacement Solenoid Valve Harness Test
Test 9 Swing Dampener Solenoid Valve Harness Test
Test 10 Directional Solenoid Valve Harness lest
Test 11 EC motor
Harness Test
Test 12 Engine stop motor Harness Test
Test 13 Emergency Relay Activation Test
Test 14 Relay Circuit test

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