Technical Manual Hitachi ZH200-5A, ZH200LC-5A Hybrid Excavator | TTDFM90-EN-00

Technical Manual Hitachi ZH200-5A, ZH200LC-5A Hybrid Excavator TTDFM90-EN-00 (Preview)

TTDFM90-EN-00
CONTENTS
INTRODUCTION
SYMBOL AND ABBREVIATION
SAFETY
SECTION AND GROUP CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Operational Performance Standard Table
Main Pump P-Q Diagram (P1, P2)
Main Pump P-Q Diagram (P3)
Sensor Activating Range
Monitor Indicating Values
Group 3 Engine Test
Engine Speed
Lubricant Consumption
Group 4 Machine Performance Test
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Leakage
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Operation of Boom Raise and Swing Function Check
Combined Operation of Boom Raise and Arm Roll-In Function Check
Clearance of Front Attachment Connecting Part
Group 5 Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
5-Spool Solenoid Valve Set Pressure
Pump 3 Center Bypass Shut-Out Control Solenoid Valve
2-Spool Solenoid Valve (for Swing Pilot Pressure Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Setting Menu
Inspection of Engine Oil Level, Hour Meter and Fuel Gauge
Fuel Gauge and Coolant Temperature Gauge
Group 3 e-Service
Outline
List of Operation Data
Snapshot Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Electrical System (Around Air Cleaner)
Electrical System (Relay, Sensor)
Electrical System (Battery)
Engine
Pump Device
Around Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Pump 3 Center Bypass Shut-Out Control Solenoid Valve
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
MC Fault Code List
ECM Fault Code List
Monitor Controller (Monitor) Fault Code List
Monitor Controller (Information) Fault Code List
Air Conditioner Controller Fault Code List
Communication Terminal Fault Code List
MC Fault Codes 11000 to 11002
MC Fault Code 11003
MC Fault Codes 11006, 11007,11009
Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005
CAN0 Harness Check
MC Fault Codes 11008, 11010
Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007, 13013, 13014
CAN1 Harness Check
MC Fault Code 11100
MC Fault Code 11101
MC Fault Codes 11200, 11202, 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11301 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Code 11400
MC Fault Code 11401
MC Fault Code 11402
MC Fault Code 11403
MC Fault Code 11406
MC Fault Code 11407
MC Fault Code 11410
MC Fault Code 11411
MC Fault Code 11427
MC Fault Code 11428
MC Fault Code 11439
MC Fault Code 11901
MC Fault Codes 11997, 11998
Monitor Controller (Information) Fault Codes 13304, 13310
Monitor Controller (Information) Fault Code 13311
Monitor Controller (Information) Fault Codes 20100 to 20114
Monitor Controller (Information) Fault Codes 20109 to 20149
Air Conditioner Controller Fault Codes 11 to 22
Air Conditioner Controller Fault Codes 43 to 92
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom in Case of Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom in Case of Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
SECTION 7 HYBRID TROUBLESHOOTING
Group 1 Standard
Operational Performance Standard Table
MPDr. Monitor Indicating Values
Relief Set Pressure (Relief Operation of Swing)
Swing Electric Motor Efficiency, Assist Alternator Motor Efficiency, Chopper Efficiency
Group 2 Diagnosing Procedure of Troubleshooting
Introduction
Fuse Inspection
Voltage and Current Measurement
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Detect Voltage
Appearance Check
Check for Ground
Instructions for Disconnecting Connectors
How to Check Power Insulation
How to use inspection equipments
Group 3 Monitor
Outline
Service Menu
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Assist Alternator Motor
Swing Device
Swing Control Solenoid Valve Unit
Swing Pilot Pressure Control Solenoid Valve Unit
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
HCU Fault Code List
HCU Fault Codes 19500 to 19503
HCU Fault Code 19503-3
HCU Fault Codes 19504, 19505
HCU Fault Codes 19506, 19507
HCU Fault Code 19508
HCU Fault Code 19509
HCU Fault Code 19511
HCU Fault Code 19512
HCU Fault Codes 19513 to 19516
Harness Check between HCU and PCU
HCU Fault Codes 19518 to 19522
CAN1 Harness Check
INV-CAN Harness Check
HCU Fault Code 19524
HCU Fault Code 19525
Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19532 to 19534
Harness Check between HCU and PCU
HCU Fault Code 19535
HCU Fault Code 19536
PCU Fault Code List
PCU Fault Code 19607
PCU Fault Codes 19611, 19612, and 19613
Harness Check between PCU and Capacitor Unit
PCU Fault Codes 19615, 19616
PCU Fault Codes 19617, 19620
Power Harness Check between PCU and Swing Electric Motor
PCU Fault Code 19618
Power Harness Check between PCU and Capacitor Unit
PCU Fault Codes 19621, 19622
PCU Fault Codes 19623, 19624
Harness Check between PCU and Swing Electric Motor (Resolver)
PCU Fault Code 19627
Harness Check between PCU and Swing Electric Motor (Thermistor)
PCU Fault Codes 19628, 19630
PCU Fault Code 19633
Harness Check between PCU and PUMP/H2 Connector
PCU Fault Code 19634
PCU Fault Code 19635
PCU Fault Codes 19637, 19638
PCU Fault Code 19641
PCU Fault Code 19642
PCU Fault Codes 19648, 19649
Group 6 Troubleshooting B
Outline
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Swing System Troubleshooting
Exchange Inspection
Applicability of Switch-Check Method
SERVICE MANUAL REVISION REQUEST FORM