Hitachi ZX300-5A ZX300LC-5A ZX300LCH-5A Hydraulic Excavator Troubleshooting Technical Manual
File Details:
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
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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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Jase Ahmir –
I have only had one issue with a manual and that was it downloaded in Spanish. Not much good to me but I did get the English version at no charge.