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Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual -PDF DOWNLOAD
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Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual
Part No : TTDAS50-EN-00
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Description
Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual
File details:
Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual
Language : English
Pages : 536
Size : 13.5 MB
Downloadable : Yes
Format : PDF
Part No : TTDAS50-EN-00
HITACHI ZX135US 6 HYDRAULIC EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL -PDF DOWNLOAD:
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Table of Contents:
Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual
TTDAS50-EN-00....................................................................................... 1 CONTENTS........................................................................................ 3 INTRODUCTION.................................................................................... 7 To The Reader............................................................................... 7 Additional References....................................................................... 7 Manual Composition.......................................................................... 7 Page Number................................................................................. 7 Trademark................................................................................... 7 Safety Alert Symbol and Headline Notations.................................................. 8 Units Used.................................................................................. 8 SYMBOL AND ABBREVIATION......................................................................... 9 SAFETY.......................................................................................... 11 Recognize Safety Information................................................................ 11 Understand Signal Words..................................................................... 11 Follow Safety Instructions.................................................................. 12 Prepare for Emergencies..................................................................... 13 Wear Protective Clothing.................................................................... 13 Protect Against Noise....................................................................... 14 Inspect Machine............................................................................. 14 General Precautions for the Cab............................................................. 15 Use Handholds and Steps..................................................................... 16 Adjust the Operator's Seat.................................................................. 16 Ensure Safety Before Rising from or Leaving Operator’s Seat................................. 17 Fasten Your Seat Belt....................................................................... 17 Move and Operate Machine Safely............................................................. 18 Operate Only from Operator's Seat........................................................... 18 Jump Starting............................................................................... 19 Keep Riders off Machine..................................................................... 19 Precautions for Operations.................................................................. 20 Investigate Job Site Beforehand............................................................. 21 Install OPG Guard........................................................................... 22 Restriction of Attachment Installation...................................................... 22 Provide Signals for Jobs Involving Multiple Machines........................................ 23 Confirm Direction of Machine to Be Driven................................................... 23 Drive Machine Safely........................................................................ 24 Avoid Injury from Rollaway Accidents........................................................ 26 Avoid Injury from Back-Over and Swing Accidents............................................. 27 Keep People Clear from Working Area......................................................... 28 Never Position the Bucket Over Anyone....................................................... 28 Avoid Undercutting.......................................................................... 29 Avoid Tipping............................................................................... 29 Never Undercut a High Bank.................................................................. 30 Dig with Caution............................................................................ 30 Operate with Caution........................................................................ 30 Avoid Power Lines........................................................................... 31 Precautions for Lightning................................................................... 31 Object Handling............................................................................. 32 Protect Against Flying Debris............................................................... 32 Park Machine Safely......................................................................... 33 Handle Fluids Safely−Avoid Fires............................................................ 33 Transport Safely............................................................................ 34 Practice Safe Maintenance................................................................... 35 Warn Others of Service Work................................................................. 36 Support Machine Properly.................................................................... 36 Stay Clear of Moving Parts.................................................................. 37 Prevent Parts from Flying................................................................... 37 Avoid Injury from Attachment Falling Accident............................................... 38 Prevent Burns............................................................................... 38 Replace Rubber Hoses Periodically........................................................... 39 Avoid High-Pressure Fluids.................................................................. 39 Prevent Fires............................................................................... 40 Evacuating in Case of Fire.................................................................. 42 Beware of Exhaust Fumes..................................................................... 42 Precautions for Welding and Grinding........................................................ 43 Avoid Heating Near Pressurized Fluid Lines.................................................. 44 Avoid Applying Heat to Lines Containing Flammable Fluids.................................... 44 Precautions for Handling Accumulator and Gas Damper......................................... 44 Remove Paint Before Welding or Heating...................................................... 45 Beware of Asbestos and Silica Dust and Other Contamination.................................. 45 Prevent Battery Explosions.................................................................. 46 Service Air Conditioning System Safely...................................................... 46 Handle Chemical Products Safely............................................................. 47 Dispose of Waste Properly................................................................... 47 Never Ride Attachment....................................................................... 48 Notes on Aftertreatment Device.............................................................. 48 Precautions for Communication Terminal...................................................... 48 Precautions for Communication Terminal Equipment............................................ 49 Notes on Protection of Operator’s Station when the Machine Rolls Over....................... 51 Before Returning the Machine to the Customer................................................ 52 SECTION AND GROUP CONTENTS...................................................................... 53 SECTION 4 OPERATIONAL PERFORMANCE TEST.......................................................... 55 Group 1 Introduction........................................................................ 57 Operational Performance Tests........................................................... 57 Preparation for Performance Tests....................................................... 58 Group 2 Standard............................................................................ 59 Operational Performance Standard Table.................................................. 59 Main Pump P-Q Diagram (P1, P2).......................................................... 69 Sensor Activating Range................................................................. 71 Monitor Indicating Values............................................................... 72 Group 3 Engine Test......................................................................... 85 Engine Speed............................................................................ 85 Lubricant Consumption................................................................... 88 Group 4 Machine Performance Test............................................................ 89 Travel Speed............................................................................ 89 Track Revolution Speed.................................................................. 90 Mistrack Check.......................................................................... 91 Travel Parking Leakage.................................................................. 92 Swing Speed............................................................................. 93 Swing Function Drift Check.............................................................. 94 Swing Motor Leakage..................................................................... 96 Maximum Swingable Slant Angle........................................................... 98 Swing Bearing Play......................................................................100 Hydraulic Cylinder Cycle Time...........................................................102 Dig Function Drift Check................................................................104 Control Lever Operating Force...........................................................108 Control Lever Stroke....................................................................109 Combined Operation of Boom Raise and Swing Function Check...............................110 Combined Operation of Boom Raise and Arm Roll-In Function Check.........................111 Clearance of Front Attachment Connecting Part...........................................112 Group 5 Component Test......................................................................113 Primary Pilot Pressure..................................................................113 Secondary Pilot Pressure................................................................115 4-Spool Solenoid Valve Set Pressure.....................................................116 2-Spool Solenoid Valve (Aftertreatment Device Regeneration Control) Set Pressure........117 Main Pump Delivery Pressure.............................................................119 Main Relief Set Pressure................................................................120 Relief Pressure (when relieving swing)..................................................126 Overload Relief Valve Set Pressure......................................................128 Main Pump Flow Rate Measurement.........................................................132 Swing Motor Drainage....................................................................140 Travel Motor Drainage...................................................................142 Group 6 Adjustment..........................................................................145 Rewrite of Aftertreatment Device Serial No..............................................145 How to Clear Fault Code.................................................................146 Procedure after Replacing DCU and ECM...................................................147 Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping............................148 How to Check Manual Regeneration Switch.................................................150 Remedy at DEF Pressure Decrease.........................................................152 Remedy at DEF Abnormal Quality..........................................................154 Clean DEF Tank..........................................................................156 Remedy when Mixing Oil in DEF Tank......................................................158 SECTION 5 TROUBLESHOOTING.......................................................................161 Group 1 Diagnosing Procedure................................................................163 Introduction............................................................................163 Diagnosis Procedure.....................................................................164 Electrical System Inspection............................................................167 Precautions for Inspection and Maintenance..............................................168 Instructions for Disconnecting Connectors...............................................170 Fuse Inspection.........................................................................172 Fusible Link Inspection.................................................................175 Battery Voltage Check...................................................................176 Alternator Check........................................................................177 Continuity Check........................................................................178 Voltage and Current Measurement.........................................................180 Check by False Signal...................................................................188 Test Wire Harness.......................................................................189 Group 2 Monitor.............................................................................191 Outline.................................................................................191 Operating Procedures of Service Menu....................................................192 Setting Menu............................................................................233 Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge...............238 Fuel Gauge, Coolant Temperature Gauge, DEF Gauge........................................239 Group 3 e-Service...........................................................................241 Outline.................................................................................241 List of Operation Data..................................................................242 Communication System....................................................................244 Group 4 Component Layout....................................................................245 Main Component..........................................................................245 Electrical System (Overview)............................................................249 Electrical System (Rear Tray)...........................................................250 Electrical System (Switch Panel)........................................................251 Electrical System (Around Air Cleaner)..................................................252 Electrical System (Relays)..............................................................253 Engine..................................................................................254 Aftertreatment Device...................................................................255 Aftertreatment Device...................................................................256 Pump Device.............................................................................257 Around Pump Device......................................................................258 Control Valve...........................................................................259 Signal Control Valve....................................................................259 Swing Device............................................................................261 Travel Device...........................................................................261 4-Spool Solenoid Valve Unit.............................................................262 Maximum Pump 1 Flow Rate Limit Control Solenoid Valve...................................262 2-Spool Solenoid Valve Unit (Aftertreatment Device Regeneration Control)................262 DEF Tank................................................................................263 DEF Supply Module.......................................................................263 Layout of Attachment Spec. Parts........................................................265 Components in Control Valve.............................................................270 Pilot Port..............................................................................288 Group 5 Troubleshooting A...................................................................293 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...............293 MC Fault Code List......................................................................295 ECM Fault Code List.....................................................................316 DCU Fault Code List.....................................................................330 Monitor Controller (Monitor) Fault Code List............................................338 Monitor Controller (Information) Fault Code List........................................339 Air Conditioner Controller Fault Code List..............................................342 Communication Terminal Fault Code List..................................................343 MC Fault Codes 11000 to 11002...........................................................345 MC Fault Code 11003.....................................................................346 MC Fault Codes 11006, 11007,11009.......................................................349 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005............................349 CAN0 Harness Check......................................................................350 ISO-CAN (Engine) Harness Check..........................................................354 MC Fault Codes 11008, 11010.............................................................357 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007............................357 CAN1 Harness Check......................................................................358 MC Fault Code 11100.....................................................................361 MC Fault Code 11101.....................................................................362 MC Fault Codes 11200 to 11202...........................................................363 MC Fault Codes 11206 to 11208...........................................................364 MC Fault Codes 11301 to 11303...........................................................365 MC Fault Codes 11304, 11307, 11325......................................................366 MC Fault Codes 11995, 11997.............................................................367 MC Fault Code 11400.....................................................................368 MC Fault Code 11401.....................................................................369 MC Fault Code 11402.....................................................................370 MC Fault Code 11403.....................................................................371 MC Fault Code 11407.....................................................................372 MC Fault Code 11408.....................................................................373 MC Fault Code 11409.....................................................................374 MC Fault Code 11410.....................................................................375 MC Fault Code 11428.....................................................................376 MC Fault Codes 11434, 11435.............................................................377 MC Fault Code 11436.....................................................................378 MC Fault Codes 11458, 11459.............................................................379 MC Fault Code 11901.....................................................................380 MC Fault Codes 20010 to 20012...........................................................381 Monitor Controller (Information) Fault Codes 13304, 13310...............................382 Monitor Controller (Information) Fault Code 13311.......................................383 Monitor Controller (Information) Fault Codes 20100 to 20114.............................384 Monitor Controller (Information) Fault Codes 20109 to 20149.............................385 Air Conditioner Controller Fault Codes 11 to 22.........................................386 Air Conditioner Controller Fault Codes 43 to 92.........................................387 Group 6 Troubleshooting B...................................................................389 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure................389 Relationship between Machine Trouble Symptoms and Related Parts.........................391 Correlation between Trouble Symptoms and Part Failures..................................418 Engine System Troubleshooting...........................................................435 All Actuator System Troubleshooting.....................................................445 Front Attachment System Troubleshooting.................................................454 Swing System Troubleshooting............................................................468 Travel System Troubleshooting...........................................................470 Blade System Troubleshooting (Option)...................................................476 Other System Troubleshooting............................................................478 Exchange Inspection.....................................................................483 How to Lowering Boom When Emergency and When Engine Stops without Hose Rupture Valve....486 How to Lowering Boom When Emergency and When Engine Stops with Hose Rupture Valve.......487 Attachment Circuit Pressure Release Procedure...........................................488 Group 7 Air Conditioner.....................................................................489 Outline.................................................................................489 Functions of Main Parts.................................................................492 Troubleshooting.........................................................................497 Air Conditioner Controller Fault Code List..............................................498 Air Conditioner Controller Fault Codes 11 to 22.........................................499 Air Conditioner Controller Fault Codes 43 to 92.........................................500 Work after Replacing Components.........................................................522 Refill Compressor Oil...................................................................523 Charge Air Conditioner with Refrigerant.................................................524 Hose and Pipe Tightening Torque.........................................................532 SERVICE MANUAL REVISION REQUEST FORM............................................................535 The Attached Diagram List.......................................................................536
Description:
Hitachi ZX135US 6 Hydraulic Excavator Technical Troubleshooting Manual
INTRODUCTION:
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 materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• 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.
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]
