Hitachi ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G Hydraulic Excavator Troubleshooting Technical Manual – PDF Download

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Hitachi ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G Hydraulic Excavator Troubleshooting Technical Manual

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Hitachi ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G Hydraulic Excavator Troubleshooting Technical Manual

• Manual Language:English
• Pages: 438 
• Size: 4.52 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL – PDF DOWNLOAD:

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Description:

Hitachi ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G 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 ZX240-5G ZX240LC-5G ZX250H-5G 250LCH-5G Hydraulic Excavator Troubleshooting Technical Manual

TTDCE-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............................................................... 59
		Sensor Activating Range............................................................. 61
		MPDr. Monitor Indicating Values..................................................... 62
	Group 3 Engine Test..................................................................... 71
		Engine Speed........................................................................ 71
		Engine Compression Pressure......................................................... 74
		Valve Clearance..................................................................... 76
		Nozzle.............................................................................. 78
		Injection Timing.................................................................... 80
		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
	Group 5 Component Test..................................................................105
		Primary Pilot Pressure..............................................................105
		Secondary Pilot Pressure............................................................107
		Solenoid Valve Set Pressure.........................................................108
		Main Pump Delivery Pressure.........................................................110
		Main Relief Set Pressure............................................................112
		Relief pressure (when relieving swing)..............................................116
		Overload Relief Valve Set Pressure..................................................118
		Main Pump Flow Rate Measurement.....................................................120
		Swing Motor Drainage................................................................128
		Travel Motor Drainage...............................................................130
	Group 6 Adjustment......................................................................133
		Engine Speed Adjustment and Engine Learning.........................................133
		Governor Lever and Fuel Cut Lever Position..........................................138
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 (Built-In Diagnosing System)...................172
		Setting Menu........................................................................205
		Inspection of Hour Meter and Fuel Gauge.............................................207
		Fuel Gauge and Coolant Temperature Gauge............................................208
	Group 3 e-Service.......................................................................209
		Outline.............................................................................209
		List of Operation Data..............................................................210
		Snapshot Data.......................................................................214
		Communication System................................................................215
	Group 4 Component Layout................................................................217
		Main Component......................................................................217
		Electrical System (Overview)........................................................218
		Engine..............................................................................219
		Electrical System (In Cab)..........................................................219
		Electrical System (Rear Tray).......................................................220
		Electrical System (Switch Panel)....................................................221
		Electrical System (Around Air Cleaner)..............................................222
		Electrical System (Relays)..........................................................223
		Pump Device.........................................................................224
		Control Valve.......................................................................225
		Signal Control Valve................................................................225
		Swing Device........................................................................227
		Travel Device.......................................................................227
		3-Spool Solenoid Valve Unit.........................................................228
		Layout of Attachment Spec. Parts....................................................230
		Components in Control Valve.........................................................234
		Pilot Port..........................................................................254
	Group 5 Troubleshooting A...............................................................259
		Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...........259
		MC Fault Code List..................................................................261
		ECF Fault Code List.................................................................271
		Monitor Controller (Monitor) Fault Code List........................................272
		Monitor Controller (Information) Fault Code List....................................273
		Air Conditioner Controller Fault Code List..........................................276
		Communication Terminal Fault Code List..............................................277
		MC Fault Codes 11000 to 11002.......................................................279
		MC Fault Code 11003.................................................................280
		ECF Fault Code 16603................................................................280
		MC Fault Codes 11006, 11007, 11009..................................................283
		ECF Fault Code 16604................................................................283
		Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005........................283
		CAN0 Harness Check..................................................................284
		MC Fault Codes 11008, 11010.........................................................287
		Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007........................287
		CAN1 Harness Check..................................................................288
		MC Fault Code 11100.................................................................291
		MC Fault Code 11101.................................................................292
		MC Fault Codes 11200, 11202.........................................................293
		MC Fault Codes 11206, 11208.........................................................294
		MC Fault Codes 11301 to 11303.......................................................295
		MC Fault Codes 11304, 11307.........................................................296
		MC Fault Code 11400.................................................................297
		MC Fault Code 11401.................................................................298
		MC Fault Code 11402.................................................................299
		MC Fault Code 11403.................................................................300
		MC Fault Code 11407.................................................................301
		MC Fault Code 11901.................................................................302
		ECF Fault Codes 16600 to 16602......................................................303
		ECF Fault Code 16605................................................................304
		ECF Fault Code 16606................................................................305
		Air Conditioner Controller Fault Codes 11 to 22.....................................306
		Air Conditioner Controller Fault Codes 43 to 92.....................................307
		Monitor Controller (Information) Fault Codes 13304, 13310...........................308
		Monitor Controller (Information) Fault Code 13311...................................309
		Monitor Controller (Information) Faul tCodes 20100 to 20114.........................310
	Group 6 Troubleshooting B...............................................................311
		Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....311
		Relationship between Machine Trouble Symptoms and Related Parts.....................313
		Correlation between Trouble Symptoms and Part Failures..............................332
		Engine System Troubleshooting.......................................................346
		All Actuator System Troubleshooting.................................................360
		Front Attachment System Troubleshooting.............................................367
		Swing System Troubleshooting........................................................379
		Travel System Troubleshooting.......................................................381
		Other System Troubleshooting........................................................386
		Exchange Inspection.................................................................387
		How to Lowering Boom in Case of Emergency and When Engine Stops.....................390
	Group 7 Air Conditioner.................................................................391
		Outline.............................................................................391
		Functions of Main Parts.............................................................394
		Troubleshooting.....................................................................399
		Air Conditioner Controller Fault Code List..........................................400
		Air Conditioner Controller Fault Codes 11 to 22.....................................401
		Air Conditioner Controller Fault Codes 43 to 92.....................................402
		Work after Replacing Components.....................................................424
		Refill Compressor Oil...............................................................425
		Charge Air Conditioner with Refrigerant.............................................426
		Hose and Pipe Tightening Torque.....................................................434
SERVICE MANUAL REVISION REQUEST FORM........................................................437
The Attached Diagram List...................................................................438

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]