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Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual (TTDAE-EN-00) – PDF Download
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- Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual
- Part No:TTDAE-EN-00
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Description
Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual (TTDAE-EN-00)
File Details:
Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual (TTDAE-EN-00)
- Manual Language:English
- Downloadable:Yes
- Pages: 496
- Size: 6.19 MB
- Format:PDF
HITACHI ZX135US-5B HYDRAULIC EXCAVATOR TECHNICAL(TROUBLESHOOTING) MANUAL (TTDAE-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual (TTDAE-EN-00)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
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, the Workshop Manual and the Engine 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.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZX135US-5B Hydraulic Excavator Technical(Troubleshooting) Manual (TTDAE-EN-00)
TTDAE-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...................................................................... 63 Sensor Activating Range.................................................................... 65 MPDr. Monitor Indicating Values............................................................ 66 Group 3 Engine Test............................................................................ 81 Engine Speed............................................................................... 81 Lubricant Consumption...................................................................... 85 Group 4 Machine Performance Test............................................................... 87 Travel Speed............................................................................... 87 Track Revolution Speed..................................................................... 88 Mistrack Check............................................................................. 89 Travel Parking Leakage..................................................................... 90 Swing Speed................................................................................ 91 Swing Function Drift Check................................................................. 92 Swing Motor Leakage........................................................................ 94 Maximum Swingable Slant Angle.............................................................. 96 Swing Bearing Play......................................................................... 98 Hydraulic Cylinder Cycle Time..............................................................100 Dig Function Drift Check...................................................................102 Control Lever Operating Force..............................................................106 Control Lever Stroke.......................................................................107 Combined Operation of Boom Raise / Swing Function Check....................................108 Combined Operation of Boom Raise / Arm Roll-In Function Check..............................109 Clearance of Front Attachment Connecting Part..............................................110 Group 5 Component Test.........................................................................111 Primary Pilot Pressure.....................................................................111 Secondary Pilot Pressure...................................................................113 4-Spool Solenoid Valve Set Pressure........................................................114 2-Spool Solenoid Valve (Muffler Filter Regeneration Control) Set Pressure..................115 Main Pump Delivery Pressure................................................................117 Main Relief Set Pressure...................................................................118 Relief Pressure (when relieving swing).....................................................124 Overload Relief Valve Set Pressure.........................................................125 Main Pump Flow Rate Measurement............................................................130 Swing Motor Drainage.......................................................................138 Travel Motor Drainage......................................................................140 Group 6 Adjustment.............................................................................143 Measuring Method of No-Load-Max Differential Pressure......................................143 Muffler Filter Differential Pressure Sensor Learning.......................................145 Rewrite of Muffler Filter Serial No........................................................146 SECTION 5 TROUBLESHOOTING..........................................................................149 Group 1 Diagnosing Procedure...................................................................151 Introduction...............................................................................151 Diagnosis Procedure........................................................................152 Electric System Inspection.................................................................155 Precautions for Inspection and Maintenance.................................................156 Instructions for Disconnecting Connectors..................................................158 Fuse Inspection............................................................................160 Fusible Link Inspection....................................................................162 Battery Voltage Check......................................................................163 Alternator Check...........................................................................164 Continuity Check...........................................................................165 Voltage and Current Measurement............................................................166 Check by False Signal......................................................................173 Test Harness...............................................................................174 Group 2 Monitor................................................................................177 Outline....................................................................................177 Operating Procedures of Service Menu.......................................................178 Setting Menu...............................................................................216 Inspection of Engine Oil Level, Hour Meter and Fuel Gauge..................................221 Fuel Gauge and Coolant Temperature Gauge...................................................222 Group 3 e-Service..............................................................................223 Outline....................................................................................223 List of Operation Data.....................................................................224 Snapshot Data..............................................................................228 Communication System.......................................................................229 Group 4 Component Layout.......................................................................231 Main Component.............................................................................231 Electrical System (Overview)...............................................................235 Electrical System (Rear Tray)..............................................................236 Electrical System (Switch Panel)...........................................................237 Electrical System (Around Air Cleaner).....................................................238 Electrical System (Relays).................................................................239 Engine.....................................................................................240 Muffler Filter.............................................................................241 Pump De....................................................................................242 Pump Device with Blade Pump (Option) Attached..............................................242 Around Pump Device.........................................................................243 Control Valve..............................................................................244 Signal Control Valve.......................................................................244 Swing Device...............................................................................246 Travel Device..............................................................................246 4-Spool Solenoid Valve Unit................................................................247 2-Spool Solenoid Valve Unit (Muffler Filter Regeneration Control)..........................247 Machines with the Blade Attached...........................................................248 Components in Control Valve................................................................250 Pilot Po...................................................................................270 Group 5 Troubleshooting A......................................................................275 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure..................275 MC Fault Code List.........................................................................277 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..............................................................325 MC Fault Code 11003........................................................................326 MC Fault Codes 11006, 11007,11009..........................................................329 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005...............................329 CAN0 Harness Check.........................................................................330 MC Fault Codes 11008, 11010................................................................333 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007...............................333 CAN1 Harness Check.........................................................................334 MC Fault Code 11100........................................................................337 MC Fault Code 11101........................................................................338 MC Fault Codes 11200, 11202................................................................339 MC Fault Codes 11206, 11208................................................................340 MC Fault Codes 11301 to 11303..............................................................341 MC Fault Codes 11304, 11307................................................................342 MC Fault Code 11410........................................................................343 MC Fault Code 11400........................................................................344 MC Fault Code 11401........................................................................345 MC Fault Code 11402........................................................................346 MC Fault Code 11403........................................................................347 MC Fault Code 11407........................................................................348 MC Fault Code 11408........................................................................349 MC Fault Code 11409........................................................................350 MC Fault Code 11428........................................................................351 MC Fault Codes 11434, 11435................................................................352 MC Fault Code 11436........................................................................353 MC Fault Codes 11458, 11459................................................................354 MC Fault Code 11901........................................................................355 MC Fault Codes 20010, 20012................................................................356 Monitor Controller (Information) Fault Codes 13304, 13310..................................357 Monitor Controller (Information) Fault Code 13311..........................................358 Air Conditioner Controller Fault Codes 11 to 22............................................359 Air Conditioner Controller Fault Codes 43 to 92............................................360 Monitor Controller (Information) Fault Codes 20100 to 20114................................361 Monitor Controller (Information) Fault Codes 20109 to 20149................................362 Group 6 Troubleshooting B......................................................................363 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure...........363 Relationship between Machine Trouble Symptoms and Related Parts............................365 Correlation between Trouble Symptoms and Part Failures.....................................388 Engine System Troubleshooting..............................................................403 All Actuator System Troubleshooting........................................................411 Front Attachment System Troubleshooting....................................................419 Swing System Troubleshooting...............................................................431 Travel System Troubleshooting..............................................................433 Other System Troubleshooting...............................................................438 Exchange Inspection........................................................................443 How to Lowering Boom in Case of Emergency and When Engine Stops............................446 How to Lowering Boom in Case of Emergency and When Engine Stops with Hose Rupture Valve....447 Group 7 Air Conditioner........................................................................449 Outline....................................................................................449 Functions of Main Parts....................................................................452 Troubleshooting............................................................................457 Air Conditioner Controller Fault Code List.................................................458 Air Conditioner Controller Fault Codes 11 to 22............................................459 Air Conditioner Controller Fault Codes 43 to 92............................................460 Work after Replacing Components............................................................482 Refill Compressor Oil......................................................................483 Charge Air Conditioner with Refrigerant....................................................484 Hose and Pipe Tightening Torque............................................................492 SERVICE MANUAL REVISION REQUEST FORM...............................................................495 The Attached Diagram List..........................................................................496
Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
