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Hitachi ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual (TTLCDE0-EN-00) – PDF Download
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- Hitachi ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual
- Part No:TTLCDE0-EN-00
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Description
Hitachi ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual (TTLCDE0-EN-00)
File Details:
Hitachi ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual (TTLCDE0-EN-00)
- Manual Language:English
- Pages: 533
- Size: 13.7 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZX210W-5A WHEELED EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL (TTLCDE0-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual (TTLCDE0-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 ZX210W-5A Wheeled Excavator Troubleshooting Technical Manual (TTLCDE0-EN-00)
TTLCDE0-EN-00............................................................................ 1 INTRODUCTION......................................................................... 3 To The Reader.................................................................... 3 Additional References............................................................ 3 Manual Composition............................................................... 3 Page Number...................................................................... 3 Safety Alert Symbol and Headline Notations....................................... 4 Units Used....................................................................... 4 SYMBOL AND ABBREVIATION.............................................................. 5 SAFETY............................................................................... 7 Recognize Safety Information..................................................... 7 Understand Signal Words.......................................................... 7 Follow Safety Instructions....................................................... 8 Prepare for Emergencies.......................................................... 9 Wear Protective Clothing......................................................... 9 Protect Against Noise............................................................ 10 Inspect Machine.................................................................. 10 General Precautions for Cab...................................................... 11 Use Handholds and Steps.......................................................... 12 Adjust the Operator's Seat....................................................... 12 Ensure Safety Before Rising from or Leaving Operator’s Seat...................... 13 Fasten Your Seat Belt............................................................ 13 Move and Operate Machine Safely.................................................. 14 Operate Only from Operator's Seat................................................ 14 Jump Starting.................................................................... 15 Keep Riders off Machine.......................................................... 15 Precautions for Operations....................................................... 16 Investigate Job Site Beforehand.................................................. 17 Install OPG Guard................................................................ 18 Restriction of Attachment Installation........................................... 19 Provide Signals for Jobs Involving Multiple Machines............................. 19 Confirm Direction of Machine to Be Driven........................................ 19 Drive Machine Safely............................................................. 20 Avoid Injury from Rollaway Accidents............................................. 21 Avoid Injury from Back-Over and Swing Accidents.................................. 22 Keep Person Clear from Working Area.............................................. 23 Never Position Bucket Over Anyone................................................ 23 Avoid Undercutting............................................................... 24 Avoid Tipping.................................................................... 24 Never Undercut a High Bank....................................................... 25 Dig with Caution................................................................. 25 Operate with Caution............................................................. 25 Avoid Power Lines................................................................ 26 Precautions for Lightning........................................................ 26 Object Handling.................................................................. 27 Protect Against Flying Debris.................................................... 27 Park Machine Safely.............................................................. 28 Handle Fluids Safely−Avoid Fires................................................. 28 Transport Safely................................................................. 29 Practice Safe Maintenance........................................................ 30 Warn Others of Service Work...................................................... 31 Support Machine Properly......................................................... 31 Stay Clear of Moving Parts....................................................... 32 Prevent Parts from Flying........................................................ 32 Avoid Injury from Attachment Falling Accident.................................... 33 Support Maintenance Properly..................................................... 33 Prevent Burns.................................................................... 34 Replace Rubber Hoses Periodically................................................ 34 Avoid High-Pressure Fluids....................................................... 35 Prevent Fires.................................................................... 35 Evacuating in Case of Fire....................................................... 37 Beware of Exhaust Fumes.......................................................... 37 Precautions for Welding and Grinding............................................. 38 Avoid Heating Near Pressurized Fluid Lines....................................... 39 Avoid Applying Heat to Lines Containing Flammable Fluids......................... 39 Precautions for Handling Accumulator and Gas Damper.............................. 39 Remove Paint Before Welding or Heating........................................... 40 Beware of Asbestos and Silicon Dust and Other Contamination...................... 40 Prevent Battery Explosions....................................................... 41 Service Air Conditioning System Safely........................................... 41 Handle Chemical Products Safely.................................................. 42 Dispose of Waste Properly........................................................ 42 Never Ride Attachment............................................................ 43 Precautions for Communication Terminal........................................... 43 Precaution for Communication Terminal Equipment.................................. 44 Notes on Protection of Operator’s Station when the Machine Rolls Over............ 46 Before Returning the Machine to the Customer..................................... 47 SECTION AND GROUP CONTENTS........................................................... 49 SECTION 4 OPERATIONAL PERFORMANCE TEST............................................... 51 Group 1 Introduction............................................................. 53 Operational Performance Tests................................................ 53 Preparation for Performance Tests............................................ 54 Group 2 Standard................................................................. 55 Operational Performance Standard Table....................................... 55 Main Pump P-Q Diagram........................................................ 67 Sensor Activating Range...................................................... 69 Monitor Indicating Values.................................................... 70 Group 3 Engine Test.............................................................. 83 Engine Speed................................................................. 83 Lubricant Consumption........................................................ 87 Group 4 Machine Performance Test................................................. 89 Travel Speed................................................................. 89 Brake Function Check......................................................... 91 Parking Brake Function Check................................................. 93 Swing Speed.................................................................. 94 Swing Function Drift Check................................................... 96 Swing Motor Leakage.......................................................... 98 Maximum Swingable Slant Angle................................................100 Swing Bearing Play...........................................................102 Hydraulic Cylinder Cycle Time................................................104 Dig Function Drift Check.....................................................107 Control Lever Operating Force................................................110 Control Lever Stroke.........................................................111 Combined Operation of Boom Raise and Swing Function Check....................112 Clearance of Front Attachment Connecting Part................................114 Lever Operating Force (Blade/Outrigger, Positioning, Auxiliary)..............115 Group 5 Component Test...........................................................117 Primary Pilot Pressure.......................................................117 Secondary Pilot Pressure.....................................................119 Steering Pump Delivery Pressure..............................................120 3-Spool Solenoid Valve Set Pressure..........................................121 Pump 2 Flow Rate Control Solenoid Valve Set Pressure.........................122 Axle Lock/Brake Solenoid Valve Set Pressure..................................123 Main Pump Delivery Pressure..................................................126 Main Relief Set Pressure.....................................................127 Relief Pressure (when relieving swing).......................................131 Overload Relief Valve Set Pressure...........................................132 Main Pump Flow Rate Measurement..............................................134 Swing Motor Drainage.........................................................142 Steering Relief Pressure.....................................................144 Brake Pressure (Front and Rear)..............................................146 Brake Accumulated Pressure...................................................149 Brake Warning Pressure (Pressure-Decreasing).................................152 Brake Warning Pressure (Pressure-Increasing).................................155 SECTION 5 TROUBLESHOOTING............................................................161 Group 1 Diagnosing Procedure.....................................................163 Introduction.................................................................163 Diagnosis Procedure..........................................................164 Electric System Inspection...................................................167 Precautions for Inspection and Maintenance...................................168 Instructions for Disconnecting Connectors....................................170 Layout of Connector..........................................................172 Fuse Inspection..............................................................174 Fusible Link Inspection......................................................177 Battery Voltage Check........................................................178 Alternator Check.............................................................179 Continuity Check.............................................................180 Voltage and Current Measurement..............................................182 Check by False Signal........................................................189 Test Harness.................................................................190 Group 2 Monitor..................................................................193 Outline......................................................................193 Operating Procedures of Service Menu.........................................194 Setting Menu.................................................................233 Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge....235 Fuel Gauge, Coolant Temperature Gauge, DEF Gauge.............................236 Group 3 e-Service................................................................237 Outline......................................................................237 List of Operation Data.......................................................238 Communication System.........................................................240 Group 4 Component Layout.........................................................241 Main Component Layout........................................................241 Electrical System (Overview).................................................246 Electrical System (Cab)......................................................248 Electrical System (Switch Panel).............................................249 Electrical System (Controllers and Relays)...................................251 Electrical System (Around Air Cleaner).......................................253 Electrical System (Relays)...................................................254 Electrical System (Lights)...................................................255 Engine.......................................................................256 Pump Device..................................................................257 Around Pump Device...........................................................258 Control Valve................................................................259 Signal Control Valve.........................................................260 Swing Device.................................................................261 Travel Shockless Valve.......................................................261 Accumulator Charging Valve...................................................261 Brake Valve..................................................................261 Solenoid Valve Unit..........................................................262 Transmission Changeover Solenoid Valve.......................................263 Travel Device................................................................263 Layout of Attachment Spec. Parts.............................................264 Auxiliary Solenoid Valve Unit (Auxiliary Flow Rate Control)..................265 Components in Control Valve..................................................266 Pilot Port...................................................................286 Group 5 Troubleshooting A........................................................291 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....291 MC Fault Code List...........................................................293 ECM Fault Code List..........................................................308 Monitor Controller (Monitor) Fault Code List.................................320 Monitor Controller (Information) Fault Code List.............................321 Air Conditioner Controller Fault Code List...................................324 Communication Terminal Fault Code List.......................................325 MC Fault Codes 11000 to 11002................................................327 MC Fault Code 11003..........................................................328 MC Fault Codes 11006, 11007,11009............................................330 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005.................330 CAN0 Harness Check...........................................................331 MC Fault Codes 11008, 11010..................................................335 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007.................335 CAN1 Harness Check...........................................................336 MC Fault Code 11100..........................................................341 MC1 Fault Code 11101.........................................................342 MC Fault Codes 11200, 11202..................................................343 MC Fault Codes 11206, 11208..................................................344 MC Fault Codes 11301 to 11303................................................345 MC Fault Codes 11305 to 11307................................................346 MC Fault Codes 11310, 11311..................................................347 MC Fault Code 11400..........................................................348 MC Fault Code 11401..........................................................349 MC Fault Code 11402..........................................................350 MC Fault Code 11403..........................................................351 MC Fault Code 11404..........................................................352 MC Fault Code 11410..........................................................353 MC Fault Code 11422..........................................................354 MC Fault Code 11423..........................................................355 MC Fault Code 11424..........................................................356 MC Fault Code 11425..........................................................357 MC Fault Code 11428..........................................................358 MC Fault Codes 11460, 11461..................................................359 MC Fault Code 11901..........................................................360 MC Fault Code 15021..........................................................361 MC Fault Codes 15531, 15532..................................................362 MC Fault Code 20008..........................................................363 MC Fault Codes 20012.........................................................364 Monitor Controller (Information) Fault Codes 13304, 13310....................365 Monitor Controller (Information) Fault Code 13311............................366 Monitor Controller (Information) Fault Codes 20100 to 20114..................367 Monitor Controller (Information) Fault Codes 20109 to 20149..................368 Air Conditioner Controller Fault Codes 11 to 22..............................369 Air Conditioner Controller Fault Codes 43 to 92..............................370 Group 6 Troubleshooting B........................................................371 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.....371 Relationship between Machine Trouble Symptoms and Related Parts..............373 Correlation between Trouble Symptoms and Part Failures.......................403 Engine System Troubleshooting................................................423 All Actuator System Troubleshooting..........................................433 Front Attachment System Troubleshooting......................................441 Swing System Troubleshooting.................................................453 Travel System Troubleshooting................................................455 Brake System Troubleshooting.................................................463 Steering System Troubleshooting..............................................467 Other System Troubleshooting.................................................469 Exchange Inspection..........................................................474 How to Lowering Boom When Emergency and When Engine Stops....................477 Air Bleeding Procedures for Transmission.....................................478 Air Bleeding Procedures for Brake (Axle).....................................480 How to Release Parking Brake in Case of Emergency and When Engine Stops......482 Recovery After Parking Brake Release.........................................483 Group 7 Air Conditioner..........................................................485 Outline......................................................................485 Functions of Main Parts......................................................488 Troubleshooting..............................................................493 Air Conditioner Controller Fault Code List...................................494 Air Conditioner Controller Fault Codes 11 to 22..............................495 Air Conditioner Controller Fault Codes 43 to 92..............................496 Work after Replacing Components..............................................518 Refill Compressor Oil........................................................519 Charge Air Conditioner with Refrigerant......................................520 Hose and Pipe Tightening Torque..............................................528 SERVICE MANUAL REVISION REQUEST FORM.................................................531 The Attached Diagram List............................................................532
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]
