Hitachi ZX 210-5B 210LC-5B 210LCN-5B 240N-5B Hydraulic Excavator Troubleshooting Technical Manual – PDF Download

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Hitachi ZX 210-5B 210LC-5B 210LCN-5B 240N-5B Hydraulic Excavator Troubleshooting Technical Manual

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Hitachi ZX 210-5B 210LC-5B 210LCN-5B 240N-5B Hydraulic Excavator Troubleshooting Technical Manual

• Manual Language:English
• Pages: 508
• Size: 6.17 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZX 210-5B 210LC-5B 210LCN-5B 240N-5B HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL – PDF DOWNLOAD:

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Description:

Hitachi ZX 210-5B 210LC-5B 210LCN-5B 240N-5B Hydraulic Excavator Troubleshooting Technical Manual

TO THE READER
 This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. The machine specification and description according to destination may be explained on this manual.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES
 Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
MANUAL COMPOSITION
 This manual consists the Technical Manual and the Workshop Manual.
• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, 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 ZX 210-5B 210LC-5B 210LCN-5B 240N-5B Hydraulic Excavator Troubleshooting Technical Manual

TTDCK-EN-00..........................................................................................  1
INTRODUCTION.........................................................................................  3
SYMBOL AND ABBREVIATION..............................................................................  5
SAFETY...............................................................................................  7
SECTION AND GROUP CONTENTS........................................................................... 47
SECTION 4
OPERATIONAL PERFORMANCE TEST............................................................... 49
	Group 1 Introduction............................................................................. 51
		Operational Performance Tests................................................................ 51
		Preparation for Performance Tests............................................................ 52
	Group 2 Standard................................................................................. 53
		Operational Performance Standard Table....................................................... 53
		Main Pump P-Q Diagram (P1, P2)............................................................... 62
		Main Pump P-Q Diagram (P3)................................................................... 63
		Sensor Activating Range...................................................................... 65
		MPDr. Monitor Indicating Values.............................................................. 66
	Group 3 Engine Test.............................................................................. 79
		Engine Speed................................................................................. 79
		Lubricant Consumption........................................................................ 82
	Group 4 Machine Performance Test................................................................. 83
		Travel Speed................................................................................. 83
		Track Revolution Speed....................................................................... 84
		Mistrack Check............................................................................... 85
		Travel Parking Leakage....................................................................... 86
		Swing Speed.................................................................................. 87
		Swing Function Drift Check................................................................... 88
		Swing Motor Leakage.......................................................................... 90
		Maximum Swingable Slant Angle................................................................ 92
		Swing Bearing Play........................................................................... 94
		Hydraulic Cylinder Cycle Time................................................................ 96
		Dig Function Drift Check..................................................................... 98
		Control Lever Operating Force................................................................101
		Control Lever Stroke.........................................................................102
		Combined Operation of Boom Raise / Swing Function Check......................................103
		Combined Operation of Boom Raise / Arm Roll-In Function Check................................104
		Clearance of Front Attachment Connecting Part................................................105
	Group 5 Component Test...........................................................................107
		Primary Pilot Pressure.......................................................................107
		Secondary Pilot Pressure.....................................................................109
		5-Spool Solenoid Valve Set Pressure..........................................................110
		2-Spool Solenoid Valve (Muffler Filter Regeneration Control) Set Pressure....................111
		Main Pump Delivery Pressure..................................................................113
		Main Relief Set Pressure.....................................................................114
		Relief pressure (when relieving swing).......................................................118
		Overload Relief Valve Set Pressure...........................................................120
		Main Pump Flow Rate Measurement..............................................................122
		Swing Motor Drainage.........................................................................132
		Travel Motor Drainage........................................................................134
	Group 6 Adjustment...............................................................................137
		Measuring Method of No-Load-Max Differential Pressure........................................137
		Muffler Filter Differential Pressure Sensor Learning.........................................139
		Rewrite of Muffler Filter Serial No..........................................................140
SECTION 5
TROUBLESHOOTING............................................................................143
	Group 1 Diagnosing Procedure.....................................................................145
		Introduction.................................................................................145
		Diagnosis Procedure..........................................................................146
		Electric System Inspection...................................................................149
		Precautions for Inspection and Maintenance...................................................150
		Instructions for Disconnecting Connectors....................................................152
		Fuse Inspection..............................................................................154
		Fusible Link Inspection......................................................................156
		Battery Voltage Check........................................................................157
		Alternator Check.............................................................................158
		Continuity Check.............................................................................159
		Voltage and Current Measurement..............................................................160
		Check by False Signal........................................................................167
		Test Harness.................................................................................168
	Group 2 Monitor..................................................................................171
		Outline......................................................................................171
		Operating Procedures of Service Menu.........................................................172
		Setting Menu.................................................................................210
		Inspection of Engine Oil Level, Hour Meter and Fuel Gauge....................................215
		Fuel Gauge and Coolant Temperature Gauge.....................................................216
	Group 3 e-Service................................................................................217
		Outline......................................................................................217
		List of Operation Data.......................................................................218
		Snapshot Data................................................................................222
		Communication System.........................................................................223
	Group 4 Component Layout.........................................................................225
		Main Component...............................................................................225
		Electrical System (Overview).................................................................227
		Electrical System (Rear Tray)................................................................228
		Electrical System (Switch Panel).............................................................229
		Electrical System (Around Air Cleaner).......................................................230
		Electrical System (Relays)...................................................................231
		Engine.......................................................................................232
		Muffler Filter...............................................................................233
		Pump Device..................................................................................234
		Around Pump Device...........................................................................235
		Control Valve................................................................................236
		Signal Control Valve.........................................................................236
		Swing Device.................................................................................238
		Travel Device................................................................................238
		5-Spool Solenoid Valve Unit..................................................................239
		2-Spool Solenoid Valve Unit (Muffler Filter Regeneration Control)............................239
		Layout of Attachment Spec. Parts.............................................................240
		Components in Control Valve..................................................................246
		Pilot Port...................................................................................268
	Group 5 Troubleshooting A........................................................................273
		Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....................273
		MC Fault Code List...........................................................................275
		ECM Fault Code List..........................................................................294
		Monitor Controller (Monitor) Fault Code List.................................................318
		Monitor Controller (Information) Fault Code List.............................................319
		Air Conditioner Controller Fault Code List...................................................322
		Communication Terminal Fault Code List.......................................................323
		MC Fault Codes 11000 to 11002................................................................324
		MC Fault Code 11003..........................................................................325
		MC Fault Codes 11006, 11007,11009............................................................328
		Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005.................................328
		CAN0 Harness Check...........................................................................329
		CAN0 (Engine) Harness Check..................................................................333
		MC Fault Codes 11008, 11010..................................................................336
		Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007.................................336
		CAN1 Harness Check...........................................................................337
		MC Fault Code 11100..........................................................................340
		MC Fault Code 11101..........................................................................341
		MC Fault Codes 11200, 11202, 11203...........................................................342
		MC Fault Codes 11206 to 11208................................................................343
		MC Fault Codes 11301 to 11303................................................................344
		MC Fault Codes 11304, 11307, 11325...........................................................345
		MC Fault Code 11400..........................................................................346
		MC Fault Code 11401..........................................................................347
		MC Fault Code 11402..........................................................................348
		MC Fault Code 11403..........................................................................349
		MC Fault Code 11406..........................................................................350
		MC Fault Code 11407..........................................................................351
		MC Fault Code 11408..........................................................................352
		MC Fault Code 11409..........................................................................353
		MC Fault Codes 11434, 11435..................................................................354
		MC Fault Code 11436..........................................................................355
		MC Fault Codes 11458, 11459..................................................................356
		MC Fault Code 11427..........................................................................357
		MC Fault Code 11428..........................................................................358
		MC Fault Code 11901..........................................................................359
		MC Fault Codes 20010, 20012..................................................................360
		Monitor Controller (Information) Fault Codes 13304, 13310....................................361
		Monitor Controller (Information) Fault Code 13311............................................362
		Air Conditioner Controller Fault Codes 11 to 22..............................................363
		Air Conditioner Controller Fault Codes 43 to 92..............................................364
		Monitor Controller (Information) Fault Codes 20100 to 20114..................................365
		Monitor Controller (Information) Fault Codes 20109 to 20149..................................366
	Group 6 Troubleshooting B........................................................................367
		Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure.............367
		Relationship between Machine Trouble Symptoms and Related Parts..............................369
		Correlation between Trouble Symptoms and Part Failures.......................................394
		Engine System Troubleshooting................................................................411
		All Actuator System Troubleshooting..........................................................419
		Front Attachment System Troubleshooting......................................................426
		Swing System Troubleshooting.................................................................442
		Travel System Troubleshooting................................................................444
		Other System Troubleshooting.................................................................450
		Exchange Inspection..........................................................................455
		How to Lowering Boom in Case of Emergency and When Engine Stops without HoseRupture Valve....458
		How to Lowering Boom in Case of Emergency and When Engine Stops with Hose Rupture Valve......459
		Attachment Circuit Pressure Release Procedure................................................460
	Group 7 Air Conditioner..........................................................................461
		Outline......................................................................................461
		Functions of Main Parts......................................................................464
		Troubleshooting..............................................................................469
		Air Conditioner Controller Fault Code List...................................................470
		Air Conditioner Controller Fault Codes 11 to 22..............................................471
		Air Conditioner Controller Fault Codes 43 to 92..............................................472
		Work after Replacing Components..............................................................494
		Refill Compressor Oil........................................................................495
		Charge Air Conditioner with Refrigerant......................................................496
		Hose and Pipe Tightening Torque..............................................................504
SERVICE MANUAL REVISION REQUEST FORM.................................................................507
The Attached Diagram List............................................................................508

Please Note:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]