Factory Technical Manual (Operational Principle) and Technical Manual (Troubleshooting) For Hitachi EX200-5 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
Number: TT160E-00
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi EX200-5 Japanese Domestic Version
Contents
1.Technical Manual (Operational Principle)
INTRODUCTION
-GENERAL
–SPECIFICATION
Specifications
Working Ranges and Machine Dimensions for Transportation
Engine
Engine Accessories
Hydraulic Devices
Electrical Equipment
–COMPONENT LAYOUT
Main Components
Electrical System (Overall System)
Electrical System (Relays)
Electrical System (Monitor and Switch Panels)
Pump and Related Parts
Other Components
-UPPERSTRUCTURE
–PUMP DEVICE
Outline
Main Pump
Regulator
Pilot Pump
N Sensor (Engine Speed Sensor)
Pump Pressure Sensor
A Sensor (Pump Displacement Angle 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)
Variable Restriction
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
–OTHERS
Pilot Shut-Off Valve
Shockless Valve
Solenoid Valve Unit
Pilot Relief Valve
-UNDERCARRIAGE
–TRAVEL DEVICE
Outline
Travel Reduction Gears
Travel Motor
Travel Brake Valve
Parking Brake
–OTHERS
Swing Bearing
Center Joint
Track Adjuster
-SYSTEM
–ELECTRICAL CIRCUIT
Outline
Electric Power Circuit (Key Switch OFF)
Preheat Circuit
Starting Circuit (Key Switch START)
Charging Circuit (Key Switch ON)
Surge Voltage Prevention Circuit Accessory Circuit
Engine Stop Circuit
–HYDRAULIC CIRCUIT
Main Circuit
Pilot Circuit
Neutral Circuit
Single Actuator Operation
Combined Operation
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Valve Control
Other Control Function
2.Technical Manual (Troubleshooting)
INTRODUCTION
SAFETY
-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
-TROBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
DrEX
DrEX Start-Up Procedure
List of Fault Code
Moniring Function
–COMPONENT LAYOUT
Main Components
Electrical System (Overall System)
Electrical System (Relays)
Electrical System (Monir and Switch Panels)
Pump and Related Parts
Control Valve
Other Components
–TROUBLESHOOTING A
Troubleshooting A Procedure
List of Fault Code
Fault Code 01,02, 03
Fault Code 04
Fault Code 05
Fault Code 06
Fault Code 07
Fault Code 08, 09
Fault Code 1011
Fault Code 12,13
Fault Code 14,15,16,17,18
Fault Code 19
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
Pump Learining
Exchange inspection Method
Pump Control Line Direct Connection Method
EC Sensor Installation and Voltage Adjustment
A Sensor Installation and Voltage Adjustment
–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 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
Inspections for Disconnecting Connectors
Fuse Continuity Test
Inspection and Replacement of Fusible Links
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Cunent Check
Replacement of Relay
–HARNESS CHECK
Circuit Check
-CICUIT DIAGRAM
Cab Harness
Engine Harness
Electrical Circuit Diagram
Relay Harness
Connectors
Air Conditioner Harness
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