Technical ManualHitachi ZX210W-5A Wheeled Excavator TTLCDE0-EN-00 (Preview)
TTLCDE0-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for Cab
Use Handholds and Steps
Adjust the Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Operate Only from Operator’s Seat
Jump Starting
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Install OPG Guard
Restriction of Attachment Installation
Provide Signals for Jobs Involving Multiple Machines
Confirm Direction of Machine to Be Driven
Drive Machine Safely
Avoid Injury from Rollaway Accidents
Avoid Injury from Back-Over and Swing Accidents
Keep Person Clear from Working Area
Never Position Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Operate with Caution
Avoid Power Lines
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Avoid Injury from Attachment Falling Accident
Support Maintenance Properly
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silicon Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Precautions for Communication Terminal
Precaution for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Before Returning the Machine to the Customer
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
Sensor Activating Range
Monitor Indicating Values
Group 3 Engine Test
Engine Speed
Lubricant Consumption
Group 4 Machine Performance Test
Travel Speed
Brake Function Check
Parking Brake Function Check
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
Clearance of Front Attachment Connecting Part
Lever Operating Force (Blade/Outrigger, Positioning, Auxiliary)
Group 5 Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Steering Pump Delivery Pressure
3-Spool Solenoid Valve Set Pressure
Pump 2 Flow Rate Control Solenoid Valve Set Pressure
Axle Lock/Brake Solenoid Valve 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
Steering Relief Pressure
Brake Pressure (Front and Rear)
Brake Accumulated Pressure
Brake Warning Pressure (Pressure-Decreasing)
Brake Warning Pressure (Pressure-Increasing)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electric System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Layout of Connector
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Setting Menu
Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge
Fuel Gauge, Coolant Temperature Gauge, DEF Gauge
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component Layout
Electrical System (Overview)
Electrical System (Cab)
Electrical System (Switch Panel)
Electrical System (Controllers and Relays)
Electrical System (Around Air Cleaner)
Electrical System (Relays)
Electrical System (Lights)
Engine
Pump Device
Around Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Shockless Valve
Accumulator Charging Valve
Brake Valve
Solenoid Valve Unit
Transmission Changeover Solenoid Valve
Travel Device
Layout of Attachment Spec. Parts
Auxiliary Solenoid Valve Unit (Auxiliary Flow Rate Control)
Components in Control Valve
Pilot Port
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
CAN1 Harness Check
MC Fault Code 11100
MC1 Fault Code 11101
MC Fault Codes 11200, 11202
MC Fault Codes 11206, 11208
MC Fault Codes 11301 to 11303
MC Fault Codes 11305 to 11307
MC Fault Codes 11310, 11311
MC Fault Code 11400
MC Fault Code 11401
MC Fault Code 11402
MC Fault Code 11403
MC Fault Code 11404
MC Fault Code 11410
MC Fault Code 11422
MC Fault Code 11423
MC Fault Code 11424
MC Fault Code 11425
MC Fault Code 11428
MC Fault Codes 11460, 11461
MC Fault Code 11901
MC Fault Code 15021
MC Fault Codes 15531, 15532
MC Fault Code 20008
MC Fault Codes 20012
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 Trouble 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
Swing System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Steering System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lowering Boom When Emergency and When Engine Stops
Air Bleeding Procedures for Transmission
Air Bleeding Procedures for Brake (Axle)
How to Release Parking Brake in Case of Emergency and When Engine Stops
Recovery After Parking Brake Release
Group 7 Air Conditioner
Outline
Functions of Main Parts
Troubleshooting
Air Conditioner Controller Fault Code List
Air Conditioner Controller Fault Codes 11 to 22
Air Conditioner Controller Fault Codes 43 to 92
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
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