PDF Technical Troubleshooting Manual Hitachi EX1900-5 Excavator - 1 MB
Resolve issues quickly and efficiently on your Hitachi EX1900-5 Excavator with this technical troubleshooting manual.
This guide is designed for experienced technicians, providing diagnostic flowcharts and procedures to pinpoint problems.
It covers the hydraulic, electrical, and mechanical systems in great detail.
Reduce downtime and repair costs with this essential diagnostic tool.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 3 ---
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-6
--- Page 4 ---
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the follwing specification can be
used.
W = 15900 kg (35060 lb): BE Backhoe
16500 kg (36380 lb): Loading Shovel
3. Position the front attachment as described in the
following.
Loading shovel: With the arm cylinder fully T142-05-03-004
extended and the bucket cylinders fully extended,
position the arm top pin height flush with the boom
foot pin height.
Backhoe: With the arm cylinders fully retracted
and the bucket cylinders fully extended, position
the arm top pin height flush with the boom foot pin
height.
4. Park the machine on a smooth slope with a
gradient of 26.8 % (15°),
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine. After five minutes, measure the
difference between the marks along the swing Measure Difference Between Marks
bearing periphery and the track frame.
2. Perform the measurement in both right and left
swing directions.
3. Perform the measurement three times in each
direction and calculate the average values.
Evaluation: Marking on the Track Frame
Refer to T4-2 Operational Performance Standard.
Marking on the Swing Bearing
Solution: T105-06-03-010
Refer to T5-4 Troubleshooting B.
T4-4-8
--- Page 5 ---
OPERATIONAL PERFORMANCE TEST / Excavator Test
BOOM RAISE/SWING COMBINED OP-
ERATION CHECK
Summary:
1. Check the combined operation performance while
operating the boom raise and swing simultane-
ously.
2. Run the engine at full speed and check if the
boom cylinders move without hesitating. T142-05-03-007
NOTE: When the bucket weight is increased by
welding wear-resist plates, boom may be-
come lower.
Preparation:
1. Empty the bucket and position the machine with
front attachment positioned as illustrated.
T142-05-03-008
2. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that co-
workers are out of the swing area before
starting the measurement.
Measurement:
1. Run the engine at the maximum speed with the
auto idle switch OFF.
2. Operate the boom raise and swing levers full
stroke. Measure the time required for the machine
to swing 90 ° and bucket tooth tip height H raised T142-05-03-009
while swinging.
3. Repeat the measurement in both directions three
times and calculate the average values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Solution:
Refer to T5-4 Troubleshooting B. H
T142-05-03-010
T4-4-18
--- Page 6 ---
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
Front Side
Delivery Hose
• P-Q Line (Torque Adjustment)
Summary:
In order to check performance of the main pump,
measure the main pump flow rate by connecting a
hydraulic tester to the delivery hose of the main
pump.
Measurement Preparation:
1. Stop the engine.
CAUTION: CAUTION:The air breather cap
may fly off if turned quickly. Slowly turn it to
release internal pressure before removing it.
2. Release air from the hydraulic oil tank by
loosening the air breather cap at the oil supply
port on the hydraulic oil tank.
T18C-04-04-006
: 4 mm Pi(Main Pump 1(Main Pump
1,3,5) 2,4,6 to be measured)
3. Connect a hydraulic tester to the delivery hose.
Upper Side
Necessary components and parts are as follows:
• Hydraulic tester (ST 6299)
• Adapter (ST 6146)
• Test hose (ST6145))
1(Main Pump
• Bolt (M 341650, M341660) 1,3,5 to be
• Pipe (ST 6139) measured) 2
A
• Flange (ST 6141) 3
Split Flange Pi(Main Pump 2,4,6)
• Split flange (4075854)
(4075854)
Test Hose (ST 6145)
: 17 mm, 19 mm, 41 mm)
Adapter (ST 6146)
: 14 mm Bolt Pipe
Hydraulic Tester(ST 6299) (M341650) (ST 6139)
4. Remove plug from the pressure check port on the Adapter (ST 6146)
Bolt Test Hose
main pump to be measured, then install the Flange (ST 6141) (M341660) (ST 6145)
adapter and pressure gauge assembly. Split Flange
T18C-04-04-007
• Adapter (4075854) Delivery Hose
• Pressure gauge assembly (ST 6934) Pressure Check Port Pressure Gauge
: 19 mm (Main Pump2,4,6) Assembly (ST 6934)
Psv 2 3
5. Purge air from the main pump.
View A
4
Adapter
Pressure Check (ST 6069)
Port
(Main Pump 1,3,5)
Adapter Pressure Gauge T18C-04-04-008
(ST 6069) Assembly (ST 6934)
T4-5-10
--- Page 7 ---
OPERATIONAL PERFORMANCE TEST / Component Test
• Pi-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics)
Summary: Measurement:
In order to check performance of the oil cooler fan 1. Measure the oil cooler fan motor drive pump flow
motor drive pump, measure the main pump flow rate rate controlled by the pump control pilot pressure
by connecting a hydraulic tester to the delivery hose signal.
of the oil cooler fan pump.
2. Turn the auto-idle switch is OFF position. Operate
Preparation: the engine control lever to fast idle position.
1. Refer to steps 1 to 3 on page T4-5-18, connect a
portable tester to the oil cooler fan motor drive 3. Adjust the reducing valve (8) set pressure to the
pump to be measured. specified pressure shown on the Pi-Q diagram of
the oil cooler fan motor drive pump (Pilot Pressure
2. Disconnect hose from regulator port Pi, and at- Characteristics).
tach plug in the disconnected hose. Measure the flow rate and engine speed at each
Connect hose (5) on regulator port Pi. specified pressure shown on the Pi-Q diagram.
(Refer to T4-2-5)
3. Connect adapters (6) (2 used) and adapter (10) to
reducing valve (8). 4. Repeat the measurement three times and calcu-
Remove plug (1) located on the manifold (13). late the average values.
Connect adapter (4) to the removed plug port.
Connect hose (7) between adapter (4) and Evaluation:
adapter (6) to port P1 on reducing valve (8). Convert the measurement results to the flow rate at
: 19 mm : 6 mm the specified pump speed by the following formulas:
QC = (Np × Q)/(i × Ne)
4. Connect tee (9) to port P2 on reducing valve (8).
Connect pressure gauge (3) and hose (5) to tee Where:
(9). QC : Converted Flow Rate
: 19 mm Q : Measured Flow Rate
-1
Np : Specified Pump Speed (2178 min )
5. Connect hose (5) to port T on reducing valve (8). i : Pump Drive Gear Speed Ratio (1.088)
Remove plug (2) from hydraulic oil tank, and con- Ne : Measure Engine Speed
nect adapter (10) and hose (11) to the removed
plug (2) hole.
: 19 mm, 22 mm
6. Purge air from the main pump.
7. Fully open the loading valve on the portable tester.
8. Start the engine. Check the pressure gauge con-
nection for any oil leakage.
T4-5-20
--- Page 8 ---
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-30
--- Page 9 ---
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENTS (Engine)
7 8
1
6
2
5
4 3 Front Side
T18C-01-02-001
9
11
T18C-01-02-002
10
T5-2-4
--- Page 10 ---
TROUBLESHOOTING / Component Layout
SWING DEVICE
1
3
2
Ｔ 144-03-02-001
1 - Swing Motor 3 - Relief Valve 5 - Make-Up Valve
T5-2-14
--- Page 11 ---
TROUBLESHOOTING / Component Layout
Bucket Open/Close Pilot Valve
(Loading shovel only)
This valve controls the pilot pressure to the bucket
open/close control valve.
No. Connecting Point Remarks
1 Shuttle Valve 2 (6) Pilot pressure for bucket close
2 Travel Pilot Valve (2) Pilot Pressure
Manifold 9 (3) Pilot pressure for parking brake release
3 Travel Pilot Valve (5) Return oil to hydraulic oil tank
4 Shuttle Valve 2 (7) Pilot pressure for bucket open
Front Side
4 1
3 2
Right Side Left Side
Rear Side
T118-05-02-030
Swing Stop Solenoid Valve
Blocks the swing pilot pressure to deactivate the
swing function when either the ladder or the fast fill-
ing panel (Option) is lowered.
No. Connecting Point Remarks
1 Left Pilot Valve (4) Pilot pressure for right swing
2 Left Pilot Valve (1) Pilot pressure for left swing
3 Shuttle Valve 4 (7) Pilot pressure for left swing
4 Shuttle Valve 4 (6) Pilot pressure for right swing
2 1
Upper Side
Right Side Left Side
3 Lower Side
4
T18C-05-02-001
T5-2-24
--- Page 12 ---
TROUBLESHOOTING / Component Layout
Manifold 11
This manifold is a pilot line connection block from
manifold 7 and shuttle valve 6, 7, 8.
No. Connecting Point Remarks
1 Manifold 7 (3) Flow rate control pressure Pi (Main Pump 5)
2 Manifold 7 (4) Flow rate control pressure Pi (Main Pump 2, 3, 4,
6): Backhoe, (Main Pump 3, 4, 6): Loading shovel
3 Manifold 7 (5) Flow rate control pressure Pi (Main Pump 1):
Backhoe, (Main Pump 1, 2): Loading shovel
4 Shuttle Valve 8 (2) Flow rate control pressure Pi (Main Pump 2, 3, 4,
6): Backhoe, (Main Pump 3, 4, 6): Loading shovel
5 Shuttle Valve 7 (3) Flow rate control pressure Pi (Main Pump 5)
6 Shuttle Valve 7 (2) Flow rate control pressure Pi (Main Pump 5)
7 Shuttle Valve 6 (2) Flow rate control pressure Pi (Main Pump 1):
Backhoe, (Main Pump 1, 2): Loading shovel
8 Shuttle Valve 6 (3) Flow rate control pressure Pi (Main Pump 1):
Backhoe, (Main Pump 1, 2): Loading shovel
Upper Side
Right Side Left Side
Lower Side
1 2 3
1, 2, 3
6 4, 5, 6
4 7, 8
5
Cross
Section A
8
7
A A A
T18C-05-02-033
T5-2-34
--- Page 13 ---
TROUBLESHOOTING / Component Layout
Travel Mode Solenoid Valve, Reducing Valve
(Travel Mode Selection)
No. Connecting Point Remarks
1 Manifold 9 (2) Parking brake release pressure
2 Center Joint → Travel Motor Travel parking brake release pressure/Travel
speed change pressure
3 Manifold 8 (2) Return oil to hydraulic oil tank
1
2
Travel Mode
Solenoid Valve Upper Side
Reducing
Valve
Left Side Right Side
Lower Side
3
T18C-05-04-005
Boom Priority Switch Valve
(Loading Shovel Only)
No. Connecting Point Remarks
1 Control Valve (22) Pilot pressure for bucket tilt-in
2 Manifold 3 (7) Pilot pressure for bucket tilt-in
3 Manifold 4 (6) Return oil to hydraulic oil tank
4 Manifold 2 (6) Pilot pressure for boom raise
2 Upper Side
1
3
Left Side Right Side
Lower Side
4
T18C-05-02-026
T5-2-44
--- Page 14 ---
TROUBLESHOOTING / Component Layout
Main Pump 3, 4
No. Connecting Point Remarks
1 Main Pump 5, 6 (1) Horsepower reducing pressure Pf
2 Main Pump 5, 6 (2) Flow rate control pressure Pi (Main Pump 5)
3 Main Pump 5, 6 (3) Pump servo assist pressure Psv
4 Main Pump 5, 6 (4) Flow rate control pressure Pi (Main Pump 6)
5 Main Pump 5, 6 (5) Horsepower increase pressure Pz
6 Main Pump 1, 2 (5) Horsepower increase pressure Pz
7 Main Pump 1, 2 (4) Flow rate control pressure Pi (Main Pump 3, 4, 6)
8 Main Pump 1, 2 (3) Pump servo assist pressure Psv
9 Main Pump 1, 2 (2) Flow rate control pressure Pi (Main Pump 5)
10 Main Pump 1, 2 (1) Horsepower reducing pressure Pf
Main Pump 3
Main Pump 4
1 2
3
4 Lower Side
5
Upper Side
T18C-05-02-029
10 9 8 7 6
Main Pump 3, 4
T18C-05-02-032
Front Side
T5-2-54
--- Page 15 ---
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE AND POTENTIAL PROBLEM
PARTS WHICH MAY CAUSE TROUBLE IF
FAILED
Engine System
Parts Controller Engine Control Component
Main ECM Accel- Pilot Auto- Battery Starter Starter Engine Engine Engine
Control- eration Pres- Idle Relay Relay 1 Relay 2 Stop Stop Stop
ler (MC) Sensor sure Switch Sole- Sole- Relay
B Sensor noid noid
Trouble Symptom Relay
E-1 Although key switch is turned to START
position, starter doesn’t rotate. • • •
E-2 Although starter rotates, engine doesn’t
start. • • • •
E-3 Even if fuel lever is operated, engine
speed doesn’t change. • • •
E-4 Even if key switch is turned OFF, engine
doesn’t stop. • { •
E-5 Engine speed doesn’t decrease with con-
trol levers in neutral (with auto-idle sys- • • •
tem ON).
E-6 Even if control levers are operated, en-
gine speed doesn’t increase(with auto- • •
idle system ON).
E-7 Engine speed doesn’t increase only
when particular function is operated (with
auto-idle system ON).
E-8 Engine stalls during operation
(malfunction of power decrease control). •
E-9 Even if pre-heat switch is pressed, air
heater doesn’t operate (difficult to start •
engine).
All Actuator System
Parts Controller Pump Control Pump
Main Power Power Power Engine Main Pump
Controller Decrease Increase Decrease Speed
(MC) B Solenoid Solenoid Solenoid Sensor 1
Trouble Symptom Valve Valve Valve Relay
A-1 All actuators are inoperable or slow. • • • • •
A-2 Malfunction of power increases control. • • • •
A-3 Even after control lever is returned to neutral, ac-
tuator doesn’t stop.
T5-4-2
--- Page 17 ---
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesn’t start.
Faulty engine unit
YES
• Check for loose harness connec- (Refer to the en-
tions beforehand. gine service man-
ual.).
Check if governor Proceed trouble-
moves fuel injec- YES shooting further by
YES following the dis-
tion pump rack to Check if any fault
engine start posi- code in governor played fault code.
tion. system is displayed YES
· Visual inspection when ECM is diag- Disconnect ECM Faulty ECM.
· Key switch: ON NO nosed. J1 connector.
Check if voltage at Check if voltage at
· Refer to Trouble- NO ECM J1 connec-
shooting A. ECM relay con-
tor terminal #23 is NO nector 1 terminal
24 V. #5 is 24 V.
Turn key switch · Key switch: ON · Key switch: ON
ON. Check if en- · Measure from the
gine stop solenoid connector reverse
is shifted. side using a clip
without disconnect-
· Visual inspection ing.
· Key switch: ON
YES Faulty engine stop
YES Check for continuity solenoid.
between engine
stop solenoid mi-
nus-side terminal Faulty ground line
(black) and vehicle of engine stop so-
frame. NO lenoid.
Check if voltage
at engine stop so-
lenoid plus-side Broken harness be-
NO terminal (white) is YES
tween engine stop
24 V. solenoid relay and
· Key switch: ON engine stop sole-
noid.
Check if voltage at
engine stop sole-
noid relay connec-
NO tor 1 terminal #5 is
24 V. YES
· Key switch: ON
· Measure from the Check if voltage at
connector reverse engine stop sole-
side using a clip noid relay connec-
NO tor 1 terminal #3 is Blown fusible link
without disconnect- #7 or broken har-
ing. 24 V.
ness between bat-
· Key switch: ON NO tery and engine
· Measure from the stop solenoid relay.
connector reverse
side using a clip with-
out disconnecting.
Connector Engine Stop Solenoid Re-
ECM J1 Connector (Black) Engine Stop Solenoid Re- Engine Stop Relay
lay Connector 1 / ECM lay Connector 2 / ECM Re-
Relay Connector 1 lay Connector 2
T146-05-03-004 T146-05-04-010 T146-05-04-003
T146-05-04-009
T5-4-12
--- Page 18 ---
TROUBLESHOOTING / Troubleshooting B
E-9 Even if preheat switch is pressed, air heater
doesn’t operate (difficult to start engine).
• This troubleshooting should be applied only when
the air heater in the engine doesn’t operate. In
case the preheat indicator only doesn’t light, refer
to Troubleshooting C.
• When the preheat switch is pressed, the air
heater is heated by electricity for 60 seconds.
When measuring voltages in the circuit, check the
voltage within 60 seconds after pressing the pre-
heat switch, or turn the preheat switch OFF and
wait for more than 60 seconds. Then, press the
preheat switch again.
• Check for loose harness connections beforehand.
Broken harness
YES between preheat
relay R terminal M
and air heater.
YES Faulty preheat re-
Check for conti- lay R.
YES nuity between
preheat relay R
Check if voltage at terminal #2 and Faulty ground line
preheat relay R vehicle frame. from preheat relay
Check if voltage NO