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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