Hitachi ZX300-5A ZX300LC-5A ZX300LCH-5A Hydraulic Excavator Troubleshooting Technical Manual – PDF Download

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Hitachi ZX300-5A ZX300LC-5A ZX300LCH-5A Hydraulic Excavator Troubleshooting Technical Manual

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Hitachi ZX300-5A ZX300LC-5A ZX300LCH-5A Hydraulic Excavator Troubleshooting Technical Manual

• Manual Language:English
• Pages: 800+
• Size: 5.98 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZX300-5A ZX300LC-5A ZX300LCH-5A HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL – PDF DOWNLOAD:

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Description:

Hitachi ZX300-5A ZX300LC-5A ZX300LCH-5A 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, 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 ZX300-5A ZX300LC-5A ZX300LCH-5A Hydraulic Excavator Troubleshooting Technical Manual

TDDW90-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 (P1, P2)...................................................... 61
		Sensor Activating Range............................................................. 63
		Monitor Indicating Values........................................................... 64
	Group 3 Engine Test..................................................................... 77
		Engine Speed........................................................................ 77
		Lubricant Consumption............................................................... 80
	Group 4 Machine Performance Test........................................................ 81
		Travel Speed........................................................................ 81
		Track Revolution Speed.............................................................. 82
		Mistrack Check...................................................................... 83
		Travel Parking Leakage.............................................................. 84
		Swing Speed......................................................................... 85
		Swing Function Drift Check.......................................................... 86
		Swing Motor Leakage................................................................. 88
		Maximum Swingable Slant Angle....................................................... 90
		Swing Bearing Play.................................................................. 92
		Hydraulic Cylinder Cycle Time....................................................... 94
		Dig Function Drift Check............................................................ 96
		Control Lever Operating Force....................................................... 99
		Control Lever Stroke................................................................100
		Combined Operation of Boom Raise and Swing Function Check...........................101
		Combined Operation of Boom Raise and Arm Roll-In Function Check.....................102
		Clearance of Front Attachment Connecting Part.......................................103
	Group 5 Component Test..................................................................105
		Primary Pilot Pressure..............................................................105
		Secondary Pilot Pressure............................................................107
		3-Spool 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
SECTION 5 TROUBLESHOOTING...................................................................135
	Group 1 Diagnosing Procedure............................................................137
		Introduction........................................................................137
		Diagnosis Procedure.................................................................138
		Electrical System Inspection........................................................141
		Precautions for Inspection and Maintenance..........................................142
		Instructions for Disconnecting Connectors...........................................144
		Fuse Inspection.....................................................................145
		Fusible Link Inspection.............................................................148
		Battery Voltage Check...............................................................149
		Alternator Check....................................................................150
		Continuity Check....................................................................151
		Voltage and Current Measurement.....................................................153
		Check by False Signal...............................................................160
		Test Wire Harness...................................................................161
	Group 2 Monitor.........................................................................163
		Outline.............................................................................163
		Operating Procedures of Service Menu................................................164
		Setting Menu........................................................................201
		Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge...........204
		Fuel Gauge and Coolant Temperature Gauge............................................205
	Group 3 e-Service.......................................................................207
		Outline.............................................................................207
		List of Operation Data..............................................................208
		Snapshot Data.......................................................................212
		Communication System................................................................213
	Group 4 Component Layout................................................................215
		Main Component......................................................................215
		Electrical System (Overview)........................................................216
		Electrical System (Rear Tray).......................................................217
		Electrical System (Switch Panel)....................................................218
		Electrical System (Around Air Cleaner)..............................................219
		Electrical System (Relays, etc.)....................................................220
		Components Related with Engine......................................................221
		Components Related with Pump Device.................................................222
		Around Pump Device..................................................................223
		Components Related with Control Valve...............................................224
		Components Related with Signal Control Valve........................................224
		Components Related with Swing Device................................................226
		Travel Device.......................................................................226
		3-Spool Solenoid Valve Unit.........................................................227
		Layout of Attachment Spec. Parts....................................................228
		Control Valve Side of Hydraulic Oil Tank............................................230
		Pilot Port..........................................................................254
	Group 5 Troubleshooting A...............................................................259
		Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...........259
		MC Fault Code List..................................................................261
		ECM Fault Code List.................................................................272
		Monitor Controller (Monitor) Fault Code List........................................296
		Monitor Controller (Information) Fault Code List....................................297
		Air Conditioner Controller Fault Code List..........................................300
		Communication Terminal Fault Code List..............................................301
		MC Fault Codes 11000 to 11002.......................................................303
		MC Fault Code 11003.................................................................304
		MC Fault Codes 11006, 11007,11009...................................................306
		Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005........................306
		CAN0 Harness Check..................................................................307
		MC Fault Codes 11008, 11010.........................................................311
		Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007........................311
		CAN1 Harness Check..................................................................312
		MC Fault Code 11100.................................................................315
		MC Fault Code 11101.................................................................316
		MC Fault Codes 11200, 11202.........................................................317
		MC Fault Codes 11206, 11208.........................................................318
		MC Fault Codes 11301 to 11303.......................................................319
		MC Fault Codes 11304, 11307.........................................................320
		MC Fault Code 11325.................................................................321
		MC Fault Code 11400.................................................................322
		MC Fault Code 11401.................................................................323
		MC Fault Code 11402.................................................................324
		MC Fault Code 11403.................................................................325
		MC Fault Code 11407.................................................................326
		MC Fault Code 11436.................................................................327
		MC Fault Codes 11458, 11459.........................................................328
		MC Fault Code 11901.................................................................329
		MC Fault Code 20011.................................................................330
		MC Fault Code 20062.................................................................331
		Monitor Controller (Information) Fault Codes 13304, 13310...........................332
		Monitor Controller (Information) Fault Code 13311...................................333
		Monitor Controller (Information) Fault Codes 20100 to 20114.........................334
		Monitor Controller (Information) Fault Codes 20109 to 20149.........................335
		Air Conditioner Controller Fault Codes 11 to 22.....................................336
		Air Conditioner Controller Fault Codes 43 to 92.....................................337
	Group 6 Troubleshooting B...............................................................339
		Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....339
		Relationship between Machine Trouble Symptoms and Related Parts.....................341
		Correlation between Trouble Symptoms and Part Failures..............................361
		Engine System Troubleshooting.......................................................375
		All Actuator System Troubleshooting.................................................383
		Front Attachment System Troubleshooting.............................................390
		Swing System Troubleshooting........................................................402
		Travel System Troubleshooting.......................................................404
		Other System Troubleshooting........................................................409
		Exchange Inspection.................................................................414
		How to Lowering Boom in Case of Emergency and When Engine Stops.....................417
	Group 7 Air Conditioner.................................................................419
		Outline.............................................................................419
		Functions of Main Parts.............................................................422
		Troubleshooting.....................................................................427
		Air Conditioner Controller Fault Code List..........................................428
		Air Conditioner Controller Fault Codes 11 to 22.....................................429
		Air Conditioner Controller Fault Codes 43 to 92.....................................430
		Work after Replacing Components.....................................................452
		Refill Compressor Oil...............................................................453
		Charge Air Conditioner with Refrigerant.............................................454
		Hose and Pipe Tightening Torque.....................................................462
SERVICE MANUAL REVISION REQUEST FORM........................................................465
The Attached Diagram List...................................................................466

Please Note:

⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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