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Hitachi ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual (TTDC390-EN-00) – PDF Download
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- Hitachi ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual
- Part No:TTDC390-EN-00
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Description
Hitachi ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual (TTDC390-EN-00)
File Details:
Hitachi ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual (TTDC390-EN-00)
- Manual Language:English
- Pages: 364
- Size: 3.94 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZX210LCN-G HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL (TTDC390-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual (TTDC390-EN-00)
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 ZX210LCN-G Hydraulic Excavator Troubleshooting Technical Manual (TTDC390-EN-00)
TTDC390-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....................................................................................... 58 Injection Pump.............................................................................................. 60 Sensor Activating Range..................................................................................... 61 MPDr. Monitor Indicating Values............................................................................. 62 Group 3 Engine Test............................................................................................. 67 Engine Speed................................................................................................ 67 Engine Compression Pressure................................................................................. 70 Valve Clearance Adjustment.................................................................................. 72 Nozzle Check................................................................................................ 74 Injection Timing............................................................................................ 76 Lubricant Consumption....................................................................................... 78 Group 4 Machine Performance Test................................................................................ 79 Travel Speed................................................................................................ 79 Track Revolution Speed...................................................................................... 80 Mistrack Check.............................................................................................. 81 Travel Parking Leakage...................................................................................... 82 Swing Speed................................................................................................. 83 Swing Function Drift Check.................................................................................. 84 Swing Motor Leakage......................................................................................... 86 Maximum Swingable Slant Angle............................................................................... 88 Swing Bearing Play.......................................................................................... 90 Hydraulic Cylinder Cycle Time............................................................................... 92 Dig Function Drift Check.................................................................................... 94 Control Lever Operating Force............................................................................... 97 Control Lever Stroke........................................................................................ 98 Combined Operation of Boom Raise / Swing Function Check..................................................... 99 Combined Operation of Boom Raise / Arm Roll-In Function Check...............................................100 Group 5 Component Test..........................................................................................101 Primary Pilot Pressure......................................................................................101 Secondary Pilot Pressure....................................................................................103 Solenoid Valve Set Pressure.................................................................................104 Main Pump Delivery Pressure.................................................................................106 Main Relief Set Pressure....................................................................................108 Relief pressure (when relieving swing)......................................................................112 Relief Pressure (When relieving Travel).....................................................................113 Overload Relief Valve Set Pressure..........................................................................114 Main Pump Flow Rate Measurement.............................................................................116 Swing Motor Drainage........................................................................................124 Travel Motor Drainage.......................................................................................126 Group 6 Adjustment..............................................................................................129 Engine Speed Adjustment and Engine Learning.................................................................129 Governor Lever and Fuel Cut Lever Position..................................................................132 SECTION 5 TROUBLESHOOTING...........................................................................................137 Group 1 Diagnosing Procedure....................................................................................139 Introduction................................................................................................139 Diagnosis Procedure.........................................................................................140 Built-In Diagnosing System Operation........................................................................143 Built-In Diagnosing Function Display List...................................................................144 Adjustment Data List........................................................................................145 Electric System Inspection..................................................................................146 Precautions for Inspection and Maintenance..................................................................147 Instructions for Disconnecting Connectors...................................................................149 Fuse Inspection.............................................................................................150 Fusible Link Inspection.....................................................................................152 Battery Voltage Check.......................................................................................153 Alternator Check............................................................................................154 Continuity Check............................................................................................155 Voltage and Current Measurement.............................................................................156 Check by False Signal.......................................................................................161 Test Harness................................................................................................162 Group 2 Component Layout........................................................................................165 Main Component Layout.......................................................................................165 Electrical Component Layout (Overview)......................................................................166 Electrical System (Relays and Related Equipment)............................................................167 Electrical System (Monitors and Switches)...................................................................168 Pump Device.................................................................................................169 Swing Device................................................................................................169 Control Valve...............................................................................................170 Signal Control Valve........................................................................................170 Solenoid Valve Unit.........................................................................................170 Travel Device...............................................................................................171 Components In Control Valve.................................................................................172 Signal Control Valve Port Location..........................................................................182 Group 3 Troubleshooting A.......................................................................................187 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...................................187 MC Fault Code List..........................................................................................189 MC Fault Codes 01 to 03.....................................................................................191 MC Fault Code 04............................................................................................192 MC Fault Code 06............................................................................................194 MC Fault Code 07............................................................................................195 MC Fault Codes 10, 11.......................................................................................196 MC Fault Codes 12, 13.......................................................................................197 MC Fault Codes 14 to 16.....................................................................................198 MC Fault Code 18............................................................................................199 MC Fault Code 19............................................................................................200 Group 4 Troubleshooting B.......................................................................................201 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure............................201 Relationship between Machine Trouble Symptoms and Related Parts.............................................203 Correlation between Trouble Symptoms and Part Failures......................................................221 Engine System Troubleshooting...............................................................................236 All Actuator System Troubleshooting.........................................................................255 Front Attachment System Troubleshooting.....................................................................261 Swing System Troubleshooting................................................................................270 Travel System Troubleshooting...............................................................................272 Other System Troubleshooting................................................................................278 Exchange Inspection.........................................................................................280 How to Lower Boom in Case of Emergency and When Engine Stops................................................282 Group 5 Troubleshooting C.......................................................................................283 Troubleshooting C (Monitor Diagnosis) Procedure.............................................................283 Malfunction of Monitor Buzzer...............................................................................285 Malfunction of Coolant Temperature Gauge....................................................................286 Malfunction of Fuel Gauge...................................................................................287 Malfunction of Hour Meter...................................................................................289 Malfunction of Light Bulb Check System......................................................................290 Malfunction of Fuel Level Indicator.........................................................................291 Malfunction of Air Filter Restriction Indicator.............................................................292 Malfunction of Overheat Indicator...........................................................................293 Malfunction of Engine Oil Pressure Indicator................................................................294 Malfunction of Alternator Indicator.........................................................................295 Malfunction of Preheat Indicator............................................................................296 Malfunction of Hydraulic Oil Filter Restriction Indicator (OP)..............................................297 Malfunction of LCD..........................................................................................298 Malfunction of Auto-Idle Indicator..........................................................................299 Malfunction of Auto-Acceleration Indicator..................................................................300 Group 6 Air Conditioner.........................................................................................301 Outline.....................................................................................................301 Functions of Main Parts.....................................................................................304 Self-Diagnosing Function....................................................................................309 Troubleshooting.............................................................................................316 Air Conditioner Controller Fault Code List..................................................................317 Air Conditioner Controller Fault Codes 21 to 22.............................................................318 Air Conditioner Controller Fault Codes 23 to 26.............................................................319 Work after Replacing Components.............................................................................340 Refill Compressor Oil.......................................................................................341 Charge Air Conditioner with Refrigerant.....................................................................342 Hose and Pipe Tightening Torque.............................................................................350 Group 7 ICX.....................................................................................................351 Outline.....................................................................................................351 ICX Fault Code List.........................................................................................356 Fault Code 1 to 4 and 6.....................................................................................357 Fault Code 7................................................................................................357 Fault Code 8................................................................................................357 Fault Code 10...............................................................................................357 Some Parts of Data In Daily Report, Frequency Distribution, Cumulative Operation Hours are Not Recorded.....358 SERVICE MANUAL REVISION REQUEST FORM................................................................................363 The Attached Diagram List...........................................................................................364
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