Hitachi EX550-5, EX550LC-5, EX600H-5, EX600LCH-5 Crawler Excavator Technical Repair Service Manual

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Information included in this Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures for the Hitachi EX550-5, EX550LC-5, EX600H-5, EX600LCH-5 Crawler Excavator.

APPLICABLE MODELS :

Hitachi Excavator EX550-5
Hitachi Excavator EX550LC-5
Hitachi Excavator EX600H-5
Hitachi Excavator EX600LCH-5

Serial No. : 07001 and up

TABLE OF CONTENTS :

(Operational Principle)

SECTION 1 GENERAL
GROUP 1 Specification
GROUP 2 Component Layout

SECTION 2 SYSTEM
GROUP 1 Control System
GROUP 2 Hydraulic System
GROUP 3 Electrical System

SECTION 3 COMPONENT OPERATION
GROUP 1 Pump Device
GROUP 2 Swing Device
GROUP 3 Control Valve
GROUP 4 Pilot Valve
GROUP 5 Travel Device
GROUP 6 Others (Upperstructure)

(Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST
GROUP 1 Introduction
GROUP 2 Engine Test
GROUP 3 Excavator Test
GROUP 4 Component Test
GROUP 5 Standard

SECTION 5 TROUBLESHOOTING
GROUP 1 Diagnosing Procedure
GROUP 2 Component Layout
GROUP 3 Troubleshooting A
GROUP 4 Troubleshooting B
GROUP 5 Troubleshooting C
GROUP 6 Electrical System Inspection

(Circuit-Diagram, Harness)

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 362

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INTRODUCTION
SAFETY

SECTION 1 GENERAL
GROUP 1 Specification
SPECIFICATIONS
WORKING RANGES / TRANSPORTING DIMENSIONS
GROUP 2 Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (1)
ELECTRICAL SYSTEM (2)
ELECTRICAL SYSTEM (3)
CONTROL VALVE
OTHERS

SECTION 2 SYSTEM
GROUP 1 Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROL
GROUP 2 Hydraulic System
OUTLINE
MAIN CIRCUIT
PILOT CIRCUIT
GROUP 3 Electrical System
OUTLINE
POWER CIRCUIT
BULB CHECK CIRCUIT
ENGINE START CIRCUIT
CHARGING CIRCUIT
ACCESSORY CIRCUIT
SURGE VOLTAGE PREVENTION CIRCUIT
ENGINE STOP CIRCUIT

SECTION 3 COMPONENT OPERATION
GROUP 1 Pump Device
OUTLINE
MAIN PUMP
REGULATORS
PILOT PUMP
GROUP 2 Swing Device
OUTLINE
SWING MOTOR
VALVE UNIT
SWING PARKING BRAKE
SWING REDUCTION GEAR
GROUP 3 Control Valve
OUTLINE
HYDRAULIC CIRCUITS
FLOW COMBINER VALVE
PUMP CONTROL VALVE
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE (With Make-Up Function)
HOLDING VALVE
ARM REGENERATIVE VALVE
GROUP 4 Pilot Valve
OUTLINE
OPERATION
GROUP 5 Travel Device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
TRAVEL MOTOR DISPLACEMENT ANGLE SHIFT
PARKING BRAKE
GROUP 6 Others (Upperstructure)
PILOT SHUT-OFF VALVE
SHOCKLESS VALVE
SOLENOID VALVE
ACCUMULATOR
Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER

SECTION 4 OPERATIONAL PERFORMANCE TEST
GROUP 1 Introduction
OPERATIONAL PERFORMANCE TESTS
PREPARATION FOR PERFORMANCE TESTS
GROUP 2 Engine Test
ENGINE SPEED
INJECTOR AND VALVE CLEARANCE AD-JUSTMENT
GROUP 3 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 OPERA-TION CHECK
GROUP 4 Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
MAIN RELIEF PRESSURE SHIFT CON-TROL PRESSURE (SA Pressure)
TRAVEL MODE SHIFT CONTROL PRES-SURE (SB Pressure)
SWING PARKING BRAKE RELEASE PRESSURE (SC Pressure)
MAIN RELIEF PRESSURE
OVERLOAD RELIEF VALVE SET PRES-SURE (PRESSURE IN POWER BOOST MODE)
MAIN PUMP FLOW TEST
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE
GROUP 5 Standard
OPERATIONAL PERFORMANCE STANDARD TABLE

SECTION 5 TROUBLESHOOTING
GROUP 1 Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Dr.EX
Dr.EX START-UP PROCEDURE
CLEARING THE SELF-DIAGNOSING FUNCTION
RETRIAL “A” (For problems with the controller (PVC and EC) )
RETRIAL “B” (For problems with the sensors)
EC-RELATED FAULT CODES
PVC-RELATED FAULT CODES
MONITORING FUNCTION
GROUP 2 Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM (2)
ELECTRICAL SYSTEM (3)
CONTROL VALVE
OTHERS
GROUP 3 Troubleshooting A
TROUBLESHOOTING A PROCEDURE
EC-RELATED FAULT CODES
PVC-RELATED FAULT CODES
FAULT CODES 01, 02, 03, 04, 06 [Failure (type-1, 2, 3, 4, 6)
FAULT CODE 05 (Signal from PVC is not Transmitted to EC)
FAULT CODES 09, 10 (Short Circuit and Discontinuity of EC Senser)
FAULT CODES 11, 12 (Short Circuit and Discontinuty of Eng. Governor Dial/Lever Angle Sensor)
FAULT CODE 13 (N Sensor Malfunction)
FAULT CODE 14 (Discontinuity 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 Codes 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 (Discontinuty of DP Sensor)
FAULT CODES 27, 28, 35, 36 (Short Circuit and Discontinuity of P Sensor)
FAULT CODES 29, 30, 37, 38 (Short Circuit and Discontinuity of A Sensor)
SENSOR OPERATING RANGE LIST
GROUP 4 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 TROUBLE-SHOOTING
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
SWING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
TROUBLESHOOTING FOR OTHER FUNC-TIONS
EC SENSOR INSTALLATION AND VOLTAGE ADJUSTMENT
INSTALLATION AND ADJUSTMENT OF THE A SENSOR
GROUP 5 Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
MALFUNCTION OF COOLANT TEMPERA-TURE GAUGE
MALFUNCTION OF FUEL GAUGE
MALFUNCTION OF INDICATOR BULB CHECK SYSTEM
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
MALFUNCTION OF COOLANT LEVEL INDICATOR
MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR
MALFUNCTION OF ALTERNATOR INDI-CATOR
MALFUNCTION OF ENGINE OIL PRES-SURE INDICATOR
MALFUNCTION OF OVERHEAT INDICA-TOR
MALFUNCTION OF FUEL LEVEL INDICA-TOR
MALFUNCTION OF AIR FILTER RESTRIC-TION INDICATOR
MALFUNCTION OF HOUR METER
MALFUNCTION OF BUZZER
MALFUNCTION OF WORK LIGHT INDICA-TOR
GROUP 6 Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE CONTINUITY TEST
FUSIBLE LINK INSPECTION AND RE-PLACEMENT
BATTERY VOLTAGE CHECK
HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS
CONTINUITY CHECK
VOLTAGE AND CURRENT CHECK
CHECK USING FALSE SIGNAL
RELAY REPLACEMENT PROCEDURE
CIRCUIT CHECK

REVISION REQUEST FORM

Circuit-Diagram
EX550-5, EX600H-5 ELECTRICAL CIRCUIT DIAGRAM 1 ( Serial No. A)
EX550-5, EX600H-5 ELECTRICAL CIRCUIT DIAGRAM 2 ( Serial No. A)
EX550-5, EX600H-5 ELECTRICAL CIRCUIT DIAGRAM 1 ( Serial No. B)
EX550-5, EX600H-5 ELECTRICAL CIRCUIT DIAGRAM 2 ( Serial No. B)
EX550-5, EX600H-5 HYDRAULIC CIRCUIT DIAGRAM (Backhoe)
EX550-5, EX600H-5 ENGINE HARNESS
EX550-5, EX600H-5 RELAY HARNESS (STD)
EX550-5, EX600H-5 CAB HARNESS 1
EX550-5, EX600H-5 CAB HARNESS 2

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