Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual (TT1JK-E-00) – PDF Download

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Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual (TT1JK-E-00)

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Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual (TT1JK-E-00)

• Manual Language:English
• Pages:626 
• Size: 4.61 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZX400R-3 ZX400LCH-3 HYDRAULIC EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (TT1JK-E-00) – PDF DOWNLOAD:

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Description:

Hitachi ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual (TT1JK-E-00)

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 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 ZX400R-3 ZX400LCH-3 Hydraulic Excavator Technical Troubleshooting Manual (TT1JK-E-00)

TT1JK-E-00..................................................................................................  1
INTRODUCTION................................................................................................  3
SAFETY......................................................................................................  5
SECTION AND GROUP CONTENTS.................................................................................. 41
SECTION 4 OPERATIONALPERFORMANCE TEST....................................................................... 43
	Group 1 Introduction.................................................................................... 45
		Operational Performance Test........................................................................ 45
		Preparation for Performance Tests................................................................... 46
	Group 2 Standard........................................................................................ 47
		Operational Performance Standard Table.............................................................. 47
		Main Pump P-Q Diagram............................................................................... 51
		Sensor Activating Range............................................................................. 53
	Group 3 Engine Test..................................................................................... 55
		Engine Speed........................................................................................ 55
		Engine Compression Pressure......................................................................... 57
		Valve Clearance..................................................................................... 58
		Lubricant Consumption............................................................................... 61
	Group 4 Excavator Test.................................................................................. 63
		Travel Speed........................................................................................ 63
		Track Revolution Speed.............................................................................. 64
		Mistrack Check...................................................................................... 65
		Travel Parking Leakage.............................................................................. 66
		Swing Speed......................................................................................... 67
		Swing Function Drift Check.......................................................................... 68
		Swing Motor Leakage................................................................................. 70
		Maximum Swingable Slant Angle....................................................................... 72
		Swing Bearing Play.................................................................................. 74
		Hydraulic Cylinder Cycle Time....................................................................... 76
		Dig Function Drift Check............................................................................ 78
		Control Lever Operating Force....................................................................... 80
		Control Lever Stroke................................................................................ 82
		Combined Operation of Boom Raise / Swing Function Check............................................. 84
		Combined Operation of Boom Raise / Arm Roll-In Function Check....................................... 86
	Group 5 Component Test.................................................................................. 87
		Primary Pilot Pressure.............................................................................. 87
		Secondary Pilot Pressure............................................................................ 90
		Solenoid Valve Set Pressure......................................................................... 92
		Main Pump Delivery Pressure......................................................................... 95
		Main Relief Set Pressure............................................................................ 96
		Relief Pressure (When relieving Swing)..............................................................100
		Overload Relief Valve Set Pressure..................................................................102
		Main Pump Flow Rate Measurement.....................................................................106
		Swing Motor Drainage................................................................................114
		Travel Motor Drainage...............................................................................117
SECTION 5 TROUBLESHOOTING...................................................................................121
	Group 1 Diagnosing Procedure............................................................................125
		Introduction........................................................................................125
		Diagnosing Procedure................................................................................126
	Group 2 Monitor Unit....................................................................................131
		Outline.............................................................................................131
		How to Use Screens..................................................................................149
		Primary Screen......................................................................................159
		Screen Display When An Alarm is Issued..............................................................160
		Contents of Alarms..................................................................................162
		Troubleshooting.....................................................................................164
		Controller Version..................................................................................166
		Monitoring..........................................................................................168
		Displaying Operating Conditions.....................................................................171
		Pump 2 Flow Rate Adjustment.........................................................................172
		Attachment Selection................................................................................174
		Time Setting........................................................................................178
		Fuel Rate Display/No Display........................................................................180
		Back Monitor Settings...............................................................................184
		Maintenance Settings................................................................................186
		Language Settings...................................................................................192
		Mail (Optional).....................................................................................194
		Keyless Hour Meter..................................................................................196
	Group 3 Dr. ZX..........................................................................................197
		Outline.............................................................................................197
		Self-Diagnostic Result..............................................................................200
		Select Controller...................................................................................202
		Main Controller.....................................................................................203
		Main Menu ..........................................................................................204
			Monitor Display.................................................................................204
			Special Function................................................................................210
			Setting.........................................................................................212
			Machine Adjustment Data List....................................................................216
			Attachment Adjustment Data List.................................................................218
			Attachment Setting..............................................................................232
			Recorded Data Display...........................................................................238
			Engine Controller...............................................................................240
		Main Menu...........................................................................................241
			Monitor Display.................................................................................241
			Recored Data Display............................................................................244
			Password Change.................................................................................245
			ICF Controller..................................................................................246
		Main Menu...........................................................................................247
			Information C/U Various Setup...................................................................247
			Date Download...................................................................................257
			Save Data Check.................................................................................258
			Password Change.................................................................................259
			Monitor Controller..............................................................................260
		Monitoring..........................................................................................261
			Various Settings................................................................................265
			Optional Function Allocation....................................................................266
			Overload Alarm Enable / Disable Selection.......................................................268
			Back Monitor Setting............................................................................270
			Operating Condition Enable / Disable Selection..................................................274
			Time Setting Function Enable / Disable Selection................................................276
			Maintenance Setting Maintenance Operation Allow / Not Allow Selection...........................278
			Notification Function Enable / Disable Selection................................................280
			Maintenance Display Item ON/OFF Selection.......................................................282
			Internal Hour Meter Synchronization.............................................................286
			Fuel Consumption Gauge Display Enable / Disable Selection.......................................287
			Password Change.................................................................................289
	Group 4 e-Shovel........................................................................................291
		Outline.............................................................................................291
		List of Daily Report Data...........................................................................292
		List of Frequency Distribution Data.................................................................295
		List of Total Operating Hours.......................................................................296
		How to Download and Upload Data of ICF..............................................................298
		Various Setup of ICF and Satellite Communication Terminal by Using Dr. ZX...........................301
		List of Fault Code..................................................................................313
		Satellite Communication System......................................................................314
	Group 5 Component Layout................................................................................317
		Main Components.....................................................................................317
		Electrical System (Overview)........................................................................318
		Electrical System (In Cab)..........................................................................320
		Electrical System (Rear Tray).......................................................................321
		Electrical System (Switch Panel)....................................................................322
		Electrical System (Utility Space)...................................................................323
		Electrical System (Relays)..........................................................................323
		Engine..............................................................................................324
		Pump Device.........................................................................................325
		Control Valve.......................................................................................326
		Signal Control Valve................................................................................326
		Solenoid Valve Unit.................................................................................327
		Travel Device.......................................................................................327
	Group 6 Troubleshooting A...............................................................................329
		Troubleshooting A Procedure.........................................................................329
		Fault Code List.....................................................................................330
			MCF.............................................................................................330
			ECM.............................................................................................348
			ICF.............................................................................................372
		Controller Hardware Failure.........................................................................378
			MCF Fault Code 11000 to 11002...................................................................378
			MCF Fault Code 11003............................................................................379
			MCF Fault Code 11004............................................................................380
			CAN Harness Check...............................................................................382
			MCF Fault Code 11101............................................................................402
		Pump Failure........................................................................................403
			MCF Fault Code 11200............................................................................403
			MCF Fault Code 11202............................................................................404
			MCF Fault Code 11206............................................................................405
			MCF Fault Code 11208............................................................................406
		Pilot Failure.......................................................................................407
			MCF Fault Code 11301............................................................................407
			MCF Fault Code 11302............................................................................408
			MCF Fault Code 11303............................................................................409
			MCF Fault Code 11304............................................................................410
			MCF Fault Code 11307............................................................................411
		Proportional Solenoid Valve Failure.................................................................412
			MCF Fault Code 11400............................................................................412
			MCF Fault Code 11401............................................................................413
			MCF Fault Code 11402............................................................................414
			MCF Fault Code 11403............................................................................415
			MCF Fault Code 11404............................................................................416
			MCF Fault Code 11405............................................................................417
		CAN Data Reception Failure..........................................................................418
			MCF Fault Code 11910, 11914, 11920..............................................................418
			CAN Harness Check (MCF Fault Code 11910, 11914, 11920)..........................................420
			MCF Fault Code 11911, 11918.....................................................................423
			CAN Harness Check(MCF Fault Code 11911, 11918)..................................................424
		Other Failures......................................................................................427
			MCF Fault Code 11901............................................................................427
		ECM, Sensor System..................................................................................428
			ECM Fault Codes 100, 102, 105, 108, 110, 157, 172...............................................428
			ECM Fault Codes 174, 636, 723, 10001............................................................429
		ECM, External Device System.........................................................................430
			ECM Fault Codes 651, 652, 653, 654, 655, 656, 1347, 10002.......................................430
		ECM, Fuel System....................................................................................431
			ECM Fault Codes 157, 633,1239, 1240.............................................................431
		ECM, Engine Protection..............................................................................432
			ECM Fault Codes 110, 190........................................................................432
			ECM Fault Codes 987, 1485.......................................................................433
		ECM, Internal Circuit System........................................................................434
			ECM Fault Codes 628, 1077, 1079,1080, 10003, 10004, 10005.......................................434
			ECM Fault Codes 10006, 10007, 10008,10009, 10010, 10011, 10013..................................435
		ECM, Communication Sysetem..........................................................................436
			ECM Fault Code 639..............................................................................436
		ICF, Satellite Terminal Fault Codes 14000 to 14003..................................................437
		ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106....................................441
		Monitor Unit Fault Code 13303.......................................................................443
		Monitor Unit Fault Code 13304.......................................................................444
		Monitor Unit Fault Codes 13306, 13308...............................................................445
		Monitor Unit Fault Code 13310.......................................................................446
		Monitor Unit Fault Code 13311.......................................................................447
		Pilot Shut-Off Lever Alarm..........................................................................448
	Group 7 Troubleshooting B...............................................................................449
		Troubleshooting B Procedure.........................................................................449
		Relationship between machine trouble Symptoms and Related Parts.....................................450
		Correlation between TroubleSymptoms and Part Failures...............................................490
		Engine System Troubleshooting.......................................................................506
		All Actuator System Troubleshooting.................................................................534
		Front Attachment System Troubleshooting.............................................................548
		Swing System Troubleshooting........................................................................568
		Travel System Troubleshooting.......................................................................572
		Other System Troubleshooting........................................................................580
		Exchange Inspection.................................................................................600
		Emergency Boom Lowering Procedure...................................................................603
		One Part of Data, Daily Report Data, Distribution Data and Total Operating Hours in Not Recorded....604
	Group 8 Electrical System Inspection....................................................................609
		Precautions for Inspection and Maintenance..........................................................609
		Instructions for Disconnecting Connectors...........................................................611
		Fuse Inspection.....................................................................................612
		Fusible Link Inspection.............................................................................613
		Battery Voltage Check...............................................................................614
		Alternator Check....................................................................................615
		Continuity Check....................................................................................616
		Voltage Check.......................................................................................618
		Check by False Signal...............................................................................620
		Test Harness........................................................................................621
SERVICE MANUAL REVISION REQUEST FORM........................................................................625
THE ATTACHED DIAGRAM LIST...................................................................................626

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