Hitachi EX120-5 Workshop Manual

$24.00

Factory Workshop Manual and Technical Manual For Hitachi EX120-5 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 EX120-5

Contents

1.Technical Manual
-GENERAL
–SPECIFICATION
Specifications
Working Ranges and Machine Dimensions for Transportation
Component Specification
–COMPONENT LAYOUT
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
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
Pump Delivery Pressure Sensor
–SWING DEVICE
Outline
Swing Motor
Brake Valve
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
-OPERATIONAL 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
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
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
Emergency Boom Lowering Procedure
–TROUBLESHOOTING C
Troubleshooting C Procedure
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 3nd Current Check
Replacement of Relay
–HARNESS CHECK
Circuit Check

2.Workshop Manual
-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
Disassemble Control Valve 2
Assemble Control Valve 2-1
Assemble Control Valve 2-2
Disassemble Control Valve 3
Assemble Control Valve 3
Disassemble Control Valve 4
Assemble Control Valve 4-1
Assemble Control Valve 4-2
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Device
Assemble Swing Device
Disassemble Swing Motor
Assemble Swing Motor
Maintenance Standard
Disassemble Valve Unit
Assemble Valve Unit
–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
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 Shockless Valve
Disassemble and Assemble Shockless Valve
–SOLENOID VALVE
Remove and Install Solenoid Valve Unit
Disassemble Propotional Solenoid Valve
Assemble Propotional Solenoid Valve
–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 and 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 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
Removeand Install Cylinder
Hydraulic Circuit Pressure Release Procedure
Disassemble Cylinder
Assemble Cylinder
Maintenance Standard
-ENGINE AND ACCESSORY
–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
–ENGINE ASSEMBLY 2 (INSPECTION AND REPAIR)
Cylinder Head
Valve Guide
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Camshaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crankshaft
Flywheel and Flywheel Housing
Timing Gear Case Cover
–ENGINE ASSEMBLY 3 (REASSEMBLY)
Piston and Connecting Rod Reassembly Steps
Cylinder Head Reassembly Steps
Rocker Arm and Rocker Shaft Reassembly Steps
Major Component Reassembly Steps 1
Major Component Reassembly Steps 2
External Parts Reassembly Steps (Left-Hand Side)
External Parts Reassembly Steps (Right-Hand Side)
Engine Tuning Operation
Engine Sectional View
–LUBRICATING SYSTEM
General Description
Oil Pump
Oil Cooler
Cooling System
General Description
Water Pump
Thermostat
–FUEL SYSTEM
General Description
Injection Nozzle
Injection Pump Calibration Data
–TURBOCHARGER
General Description
Turbocharger Identification
Inspection and Repair
–AIR COMPRESSOR
General Description
Disassembly Steps
Inspection and Repairs
Reassembly Steps
–ENGINE ELECTRICALS
Starter Motor Identification
Starter Main Data 3nd Specifications
Starter Motor Sectional View
Starter Motor Exploded View
Alternator Identification
Main D3ta and Specifications
Alternator Sectional View
Alternator Exploded View
–Troubleshooting
HARD STARTING
Starter Inoperative
Starter Operates but
ENGINE DOES NOT TURN OVER
Engine Turns Over but Does not Starts
Though Fuel is Bearing Delivered to the Injection Pump
Engine Turns Over but Does not Start
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption1
Excessive Oil Consumption1
Overheating1
Whity Exhaust Smoke1
Darkish Exhaust Smoke1
Oil Pressure does not Rise1
Abnormal Engine Noise1
–SPECIAL TOOL LIST
Special Tool List
–CONVERSION TABLE
Length
Area
Volume
Mass
Pressure
Torque
Temperature