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Hitachi Troubleshooting Manual ZX 110 110M 120 130 130LCN 12 – PDF Download
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Description
Hitachi Troubleshooting Manual ZX 110 110M 120 130 130LCN 12
FILE DETAILS:
Hitachi Troubleshooting Manual ZX 110 110M 120 130 130LCN 12
LANGUAGE:ENGLISH
PAGES:477
DOWNLOADABLE:YES
FILE TYPE:PDF
HITACHI TROUBLESHOOTING MANUAL ZX 110 110M 120 130 130LCN 12 – PDF DOWNLOAD:
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DESCRIPTION:
Hitachi Troubleshooting Manual ZX 110 110M 120 130 130LCN 12
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. • Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures
TABLE OF CONTENTS:
Hitachi Troubleshooting Manual ZX 110 110M 120 130 130LCN 12
INDEX.............................................................................................................. 1 INDEX(TT).......................................................................................................... 2 INTRODUCTION....................................................................................................... 3 SAFETY............................................................................................................. 7 SECTION 4 OPERATIONAL PERFORMANCE TEST............................................................................. 38 Introduction................................................................................................... 40 OPERATIONAL PERFORMANCE TESTS.............................................................................. 40 PREPARATION FOR PERFORMANCE TESTS.......................................................................... 41 Standard....................................................................................................... 42 ZAXIS110 OPERATIONAL PERFORMANCE STANDARD TABLE............................................................ 42 ZAXIS110M OPERATIONAL PERFORMANCE STANDARD TABLE........................................................... 46 ZAXIS120/130/130LCN OPERATIONAL PERFORMANCE STANDARD TABLE................................................. 50 ZAXIS125US OPERATIONAL PERFORMANCE STANDARD TABLE.......................................................... 54 ZAXIS135US OPERATIONAL PERFORMANCE STANDARD TABLE.......................................................... 58 ZAXIS135UR OPERATIONAL PERFORMANCE STANDARD TABLE.......................................................... 62 MAIN PUMP P-Q DIAGRAM...................................................................................... 67 INJECTION PUMP............................................................................................. 69 ZAXIS110 DR.ZX MONITOR INDICATING VALUES................................................................... 71 ZAXIS110M DR.ZX MONITOR INDICATING VALUES.................................................................. 75 ZAXIS120/130/130LCN DR.ZX MONITOR INDICATING VALUES........................................................ 79 ZAXIS125US DR.ZX MONITOR INDICATING VALUES................................................................. 83 ZAXIS135US DR.ZX MONITOR INDICATING VALUES................................................................. 87 ZAXIS135UR DR.ZX MONITOR INDICATING VALUES................................................................. 91 SENSOR OPERATIONAL RANGE TABLE............................................................................. 96 Engine Test.................................................................................................... 98 ENGINE SPEED............................................................................................... 98 ENGINE COMPRESSION PRESSURE................................................................................101 VALVE CLEARANCE ADJUSTMENT.................................................................................103 NOZZLE CHECK...............................................................................................105 INJECTION TIMING...........................................................................................107 LUBRICANT CONSUMPTION......................................................................................109 Excavator Test.................................................................................................110 TRAVEL SPEED...............................................................................................110 TRACK REVOLUTION SPEED.....................................................................................111 MISTRACK CHECK.............................................................................................112 TRAVEL PARKING FUNCTION CHECK..............................................................................113 SWING SPEED................................................................................................114 SWING FUNCTION DRIFT CHECK.................................................................................115 SWING MOTOR LEAKAGE........................................................................................117 MAXIMUM SWINGABLE SLANT ANGLE..............................................................................119 SWING BEARING PLAY.........................................................................................120 HYDRAULIC CYLINDER CYCLE TIME..............................................................................121 DIG FUNCTION DRIFT CHECK...................................................................................123 CONTROL LEVER OPERATING FORCE..............................................................................127 CONTROL LEVER STROKE.......................................................................................129 BUCKET/CAB COLLISION PREVENTION SYSTEM (ZAXIS135UR ONLY)...................................................131 COMBINED BOOM RAISE/SWING FUNCTION CHECK...................................................................133 BOOM RAISE AND ARM ROLL-IN COMBINED OPERATION..............................................................134 Component Test.................................................................................................136 PRIMARY PILOT PRESSURE.....................................................................................136 SECONDARY PILOT PRESSURE...................................................................................139 SOLENOID VALVE SET PRESSURE................................................................................141 MAIN PUMP DELIVERY PRESSURE................................................................................144 MAIN RELIEF VALVE SET PRESSURE.............................................................................145 RELIEF PRESSURE (When relieving Swing).....................................................................149 RELIEF PRESSURE (When relieving Travel)....................................................................151 OVERLOAD RELIEF VALVE SET PRESSURE.........................................................................153 MAIN PUMP FLOW RATE MEASUREMENT............................................................................157 SWING MOTOR DRAINAGE.......................................................................................163 TRAVEL MOTOR DRAINAGE......................................................................................167 Adjustment.....................................................................................................172 ASSEMBLY AND ADJUSTMENT OF LINK FOR ARM ANGLE SENSOR (ZAXIS135UR ONLY).....................................172 ADJUSTING METHOD OF FRONT ACCELERATION SPEED AND DECELERATION SPEED (ZAXIS135UR ONLY)......................173 INITIAL SETTING OF ANGLE SENSOR (ZAXIS135UR ONLY)..........................................................174 INITIALIZING THE DEPTH LIMIT CONTROL SYSTEM (ZAXIS135UR ONLY)..............................................175 ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING................................................................177 GOVERNOR LEVER AND FUEL CUT LEVER POSITION.................................................................179 SECTION 5 TROUBLESHOOTING.......................................................................................... 0 General........................................................................................................186 INTRODUCTION...............................................................................................186 DIAGNOSING PROCEDURE.......................................................................................187 BUILT-IN DIAGNOSING SYSTEM OPERATION.......................................................................191 BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST..................................................................192 Dr.ZX OPERATION............................................................................................193 Dr.ZX FAULT CODE LIST (MC).................................................................................195 FAULT CODE LIST (AUTO-MARCCINO CONTROLLER) (ZAXIS135UR ONLY)...............................................197 Dr.ZX MONITORING ITEM LIST (MC)............................................................................201 Dr.ZX MONITORING ITEM LIST (AUTO-MARCCINO CONTROLLER) (ZAXIS135UR ONLY)....................................203 Dr. ZX SPECIAL FUNCTION....................................................................................204 Dr.ZX SERVICE MODE (MC)....................................................................................205 ADJUSTMENT DATA LIST.......................................................................................217 Component Layout...............................................................................................222 MAIN COMPONENT LAYOUT......................................................................................222 ELECTRICAL COMPONENT LAYOUT (Overview).....................................................................225 ELECTRICAL SYSTEM (Relays and Related Equipment)...........................................................228 ELECTRICAL SYSTEM (Monitors and Switches)..................................................................231 PUMP DEVICE................................................................................................233 SWING DEVICE...............................................................................................234 CONTROL VALVE..............................................................................................234 SIGNAL CONTROL VALVE.......................................................................................234 SOLENOID VALVE UNIT........................................................................................234 8-UNIT SOLENOID VALVE UNIT.................................................................................235 BLADE CONTROL VALVE........................................................................................235 POSITIONING CONTROL VALVE..................................................................................235 TRAVEL DEVICE..............................................................................................235 COMPONENTS IN CONTROL VALVE................................................................................237 SIGNAL CONTROL VALVE PORT LOCATION.........................................................................247 Troubleshooting A..............................................................................................252 TROUBLESHOOTING A PROCEDURE................................................................................252 FAULT CODE LIST............................................................................................253 FAULT CODE 01, 02, 03......................................................................................254 FAULT CODE 04..............................................................................................254 FAULT CODE 06..............................................................................................255 FAULT CODE 07..............................................................................................256 FAULT CODE 10, 11..........................................................................................257 FAULT CODE 12, 13..........................................................................................258 FAULT CODE 14, 15, 16, 18..................................................................................259 FAULT CODE 19..............................................................................................260 Troubleshooting B..............................................................................................262 TROUBLESHOOTING B PROCEDURE................................................................................262 RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS............................................263 CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES.....................................................281 ENGINE SYSTEM TROUBLESHOOTING..............................................................................294 ALL ACTUATOR SYSTEM TROUBLESHOOTING........................................................................315 FRONT ATTACHMENT SYSTEM TROUBLESHOOTING....................................................................321 SWING SYSTEM TROUBLESHOOTING...............................................................................333 TRAVEL SYSTEM TROUBLESHOOTING..............................................................................336 BLADE SYSTEM TROUBLESHOOTING (ZAXIS135UR ONLY).............................................................343 OTHER SYSTEM TROUBLESHOOTING...............................................................................347 EXCHANGE INSPECTION........................................................................................373 EMERGENCY BOOM LOWERING PROCEDURE..........................................................................375 Troubleshooting C..............................................................................................376 TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE..................................................376 MALFUNCTION OF COOLANT TEMPERATURE GAUGE...................................................................377 MALFUNCTION OF FUEL GAUGE..................................................................................379 MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM................................................................381 MALFUNCTION OF PREHEAT INDICATOR...........................................................................382 MALFUNCTION OF ENGINE OIL LEVEL INDICATOR..................................................................383 MALFUNCTION OF COOLANT LEVEL INDICATOR.....................................................................385 MALFUNCTION OF ALTERNATOR INDICATOR........................................................................387 MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR...............................................................389 MALFUNCTION OF OVERHEAT INDICATOR..........................................................................391 MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR............................................................393 MALFUNCTION OF BUZZER......................................................................................395 MALFUNCTION OF LCD.........................................................................................397 MALFUNCTION OF HOUR METER..................................................................................398 MALFUNCTION OF HYDRAULIC OIL FILTER INDICATOR (Optional)...................................................399 Troubleshooting D..............................................................................................402 TROUBLESHOOTING D PROCEDURE (ZAXIS135UR ONLY)..............................................................402 FAULT CODE LIST (AUTO-MARCCINO CONTROLLER) (ZAXIS135UR ONLY)...............................................403 FAULT CODE 05..............................................................................................407 FAULT CODE 06..............................................................................................407 FAULT CODE 07..............................................................................................408 FAULT CODE 08..............................................................................................408 FAULT CODE 11 to 13, 17....................................................................................409 FAULT CODE 14 to 16, 19 to 22..............................................................................411 FAULT CODE 37, 38, 40, 41, 42, 44..........................................................................413 FAULT CODE 43, 45, 47, 48 ................................................................................414 FAULT CODE 50 to 52 .......................................................................................415 FAULT CODE 53..............................................................................................417 FAULT CODE 60 to 63........................................................................................419 FAULT CODE 80 to 83........................................................................................420 FAULT CODE 90..............................................................................................421 FAULT CODE 91..............................................................................................422 FAULT CODE 92..............................................................................................423 Electrical System Inspection...................................................................................426 PRECAUTIONS FOR INSPECTION AND MAINTENANCE.................................................................426 INSTRUCTIONS FOR DISCONNECTING CONNECTORS..................................................................428 FUSE INSPECTION............................................................................................429 FUSIBLE LINK INSPECTION....................................................................................431 BATTERY VOLTAGE CHECK......................................................................................432 HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS................................................................433 CONTINUITY CHECK...........................................................................................434 VOLTAGE AND CURRENT MEASUREMENT............................................................................436 CHECK BY FALSE SIGNAL......................................................................................442 TEST HARNESS...............................................................................................443 ICX............................................................................................................446 OUTLINE....................................................................................................446 ICX FAULT CODE LIST........................................................................................451 FAULT CODE 1 TO 4 AND 6....................................................................................452 FAULT CODE 7 TO 10.........................................................................................452 SOME PARTS OF DATA IN DAILY REPORT, FREQUENCY DISTRIBUTION, CUMULATIVE OPERATION HOURS ARE NOT RECORDED....453 THE ATTACHED DIAGRAM LIST..........................................................................................456 ZX110/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM................................................................457 ZX110/120/130/130LCN CONNECTORS................................................................................458 ZX125US/135US ELECTRICAL CIRCUIT DIAGRAM.......................................................................459 ZX125US/135US CONNECTORS.......................................................................................460 ZX135UR ELECTRICAL CIRCUIT DIAGRAM.............................................................................461 ZX135UR CONNECTORS.............................................................................................462 ZX110/120/130/130LCN CAB HARNESS...............................................................................463 ZX125US/135US CAB HARNESS......................................................................................464 ZX135UR CAB HARNESS............................................................................................465 ZX110/120/130/130LCN ENGINE HARNESS............................................................................466 ZX125US/135US ENGINE HARNESS...................................................................................467 ZX135UR ENGINE HARNESS.........................................................................................468 ZX110/120/130/130LCN MONITOR HARNESS...........................................................................469 ZX135UR CONSOLE HARNESS........................................................................................470 ZX110/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM.................................................................471 ZX125US/135US HYDRAULIC CIRCUIT DIAGRAM........................................................................472 ZX135UR HYDRAULIC CIRCUIT DIAGRAM..............................................................................473 SERVICE MANUAL REVISION REQUEST FORM...............................................................................476
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
