Hitachi Zaxis ZX210-5G 210LC-5G Hydraulic Excavator Operation Test Technical Manual TM13074X19

Contents:
General Information
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
Store Attachments Safely
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
FCC Notifications to User
Notes on Protection of Operator’s Station When the Machine Rolls Over
Before Returning the Machine to the Customer
Diagnostics
Main Controller (MCZ) Diagnostic Trouble Codes
Main Controller (MCZ) Diagnostic Trouble Codes
Controller Area Network 0 (CAN 0) Circuit Diagnostics
Controller Area Network 1 (CAN 1) Circuit Diagnostics
Interface Controller Area Network (N-CAN) Diagnostics
011000.02 – Abnormal EEPROM
011001.02 – Abnormal RAM
011002.02 – Abnormal A/D Converter
011003.03 – Abnormal Sensor Voltage
011006.02 – Engine Controller (ECF) Communication Error
011007.02 – (CAN 0) Data Converter Communication Error 1
011008.02 – (CAN 1) Data Converter Communication Error 2
011009.02 – (CAN 0) Monitor Controller Communication Error 1
011010.02 – (CAN 1) Monitor Controller Communication Error 2
011100.02 – Abnormal Engine Speed
011101.03 – Engine Control Dial Sensor Circuit High Input
011101.04 – Engine Control Dial Sensor Circuit Low Input
011200.03 – Pump 1 Delivery Pressure Sensor Circuit High Input
011200.04 – Pump 1 Delivery Pressure Sensor Circuit Low Input
011202.03 – Pump 2 Delivery Pressure Sensor Circuit High Input
011202.04 – Pump 2 Delivery Pressure Sensor Circuit Low Input
011206.03 – Pump 1 Flow Control Pressure Sensor Circuit High Input
011206.04 – Pump 1 Flow Control Pressure Sensor Circuit Low Input
011208.03 – Pump 2 Flow Control Pressure Sensor Circuit High Input
011208.04 – Pump 2 Flow Control Pressure Sensor Circuit Low Input
011301.03 – Swing Pilot Pressure Sensor Circuit High Input
011301.04 – Swing Pilot Pressure Sensor Circuit Low Input
011302.03 – Boom Up Pilot Pressure Sensor Circuit High Input
011302.04 – Boom Up Pilot Pressure Sensor Circuit Low Input
011303.03 – Arm In Pilot Pressure Sensor Circuit High Input
011303.04 – Arm In Pilot Pressure Sensor Circuit Low Input
011304.03 – Travel Pilot Pressure Sensor Circuit High Input
011304.04 – Travel Pilot Pressure Sensor Circuit Low Input
011307.03 – Front Attachment Pilot Pressure Sensor Circuit High Input
011307.04 – Front Attachment Pilot Pressure Sensor Circuit Low Input
011400.02 – Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback
011400.03 – Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current
011400.04 – Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current
011401.02 – Torque Control Solenoid Valve Abnormal Feedback
011401.03 – Torque Control Solenoid Valve Feedback High Current
011401.04 – Torque Control Solenoid Valve Feedback Low Current
011402.02 – 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback
011402.03 – 3-Spool Solenoid Valve Unit (SF) Feedback High Input
011402.04 – 3-Spool Solenoid Valve Unit (SF) Feedback Low Input
011403.02 – 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback
011403.03 – 3-Spool Solenoid Valve Unit (SC) Feedback High Input
011403.04 – 3-Spool Solenoid Valve Unit (SC) Feedback Low Input
011404.02 – 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback
011404.03 – 3-Spool Solenoid Valve Unit (SG) Feedback High Input
011404.04 – 3-Spool Solenoid Valve Unit (SG) Feedback Low Input
011457.02 – 2-Speed Activation Solenoid Disconnected or Not Present
011458.02 – Selector Valve Solenoid Valve Disconnected or Not Present
011901.03 – Hydraulic Oil Temperature Sensor Circuit High Input
011901.04 – Hydraulic Oil Temperature Sensor Circuit Low Input
Engine Controller (ECF) Diagnostic Trouble Codes
Engine Controller (ECF) Diagnostic Trouble Codes
011600.02 – Abnormal EEPROM
011601.02 – Abnormal RAM
011602.02 – Abnormal A/D Conversion
011603.03 – Abnormal Sensor Voltage
011604.02 – Abnormal CAN Communication
016605.02 – Abnormal Engine Speed
016606.03 – Abnormal EC Angle Sensor High Voltage
016606.04 – Abnormal EC Angle Sensor Low Voltage
016607.02 – Target Engine Speed Sent From Main Controller
Monitor Controller (DSZ) Diagnostic Trouble Codes
Monitor Controller (DSZ) Diagnostic Trouble Codes
013002.02 – Engine Controller (ECF) Communication Error
013003.02 – Main Controller (MCZ) Communication Error 1
013004.02 – Main Controller (MCZ) Communication Error 2
013005.02 – Monitor Controller (DSZ) Communication Error 1
013006.02 – Monitor Controller (DSZ) Communication Error 2
013007.02 – Machine Controller (BCZ) Communication Error
013303.02 – Abnormal Monitor Internal Temperature Sensor
013304.02 – Alternator Alarm
013310.03 – Shorted Circuit in Coolant Temperature Sensor
013311.03 – Fuel Level Sensor Open Circuit
013311.04 – Fuel Level Sensor Shorted Circuit
014001.02 – Flash Memory Read/Write Error
014002.02 – External RAM Read/Write Error
014003.02 – Abnormal EEPROM
014006.02 – Communication Terminal:Communication Error
014008.02 – Abnormal Internal RAM
014021.02 – Communication Terminal Security Error
014022.02 – SIM Card Error
014023.02 – Security Error
020100.02 – Overheat Alarm
020101.02 – Engine Warning Alarm
020102.02 – Engine Oil Pressure Alarm
020105.02 – Hydraulic Oil Filter Restriction Alarm
020106.02 – Air Cleaner Restriction Alarm
020109.02 – Pilot Control Shutoff Lever Alarm
020113.02 – System Error Alarm
020114.02 – Overheat Alarm
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
11 – Open Circuit in Air Recirculation Sensor
12 – Short-Circuited Air Recirculation Sensor
13 – Open Circuit in Ambient Air Temperature Sensor
14 – Short-Circuited Ambient Air Temperature Sensor
18 – Short-Circuited Solar Radiation Sensor
21 – Open Circuit in Air Conditioner Freeze Control Switch
22 – Short-Circuited Air Conditioner Freeze Control Switch
43 – Abnormal Air Conditioner and Heater Blower Port Change Servomotor
44 – Abnormal Air Conditioner and Heater Mixer Servomotor
51 – Abnormal Air Conditioner High/Low Pressure Switch
91 – Communication Error
92 – CAN Bus Off Error
Operational Checkout Procedure
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Isuzu Engine
Engine Fuel System Component Location
Engine Cooling System Component Location
Cold Weather Starting Aid
Engine Speed Control System Operation
Diagnostic Information
Isuzu Engine
Adjustments
Isuzu Engine
Engine Learning Procedure
Engine Speed Adjustment
Engine Fuel Shutoff Adjustment
Tests
Isuzu Engine
Electrical System
System Information
Electrical Diagram Information
System Diagrams
Explanation of Wire Markings
Fuse and Relay Specifications
System Functional Schematic, Component Location, and Wiring Diagram Master Legend
System Functional Schematic
Cab Harness (W1) Component Location
Cab Harness (W1) Wiring Diagram
Machine Harness (W2) Component Location
Machine Harness (W2) Wiring Diagram
Monitor Harness (W3) Component Location
Monitor Harness (W3) Wiring Diagram
Pump Harness (W8) Component Location
Pump Harness (W8) Wiring Diagram
Pilot Shutoff Switch Harness (W11) Component Location
Pilot Shutoff Switch Harness (W11) Wiring Diagram
Auxiliary Fuse Box Harness (W13) Component Location
Auxiliary Fuse Box Harness (W13) Wiring Diagram
Multi-Function Pilot Control Lever Harness (W15) Component Location
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram
Travel Alarm Cancel Switch Harness (W16) Component Location
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram
Attachment Harness (W17) Component Location
Attachment Harness (W17) Wiring Diagram
Attachment Interface Harness (W18) Component Location
Attachment Interface Harness (W18) Wiring Diagram
Rear Camera Harness (W19) Component Location
Rear Camera Harness (W19) Wiring Diagram
9-Pin Service ADVISORâ„¢ Connector (W20) Component Location
9-Pin Service ADVISORâ„¢ Connector (W20) Wiring Diagram
Pilot Shutoff Solenoid Harness (W21) Component Location
Pilot Shutoff Solenoid Harness (W21) Wiring Diagram
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram
Travel Alarm Cancel Switch Sub Harness (W25) Component Location
Travel Alarm Cancel Switch Sub Harness (W25) Wiring Diagram
Travel Alarm Harness (W26) Component Location
Travel Alarm Harness (W26) Wiring Diagram
Solenoid Harness (W28) Component Location
Solenoid Harness (W28) Wiring Diagram
Starter Switch Harness (W29) Component Location
Starter Switch Harness (W29) Wiring Diagram
Data Converter Harness (W30) Component Location
Data Converter Harness (W30) Wiring Diagram
Data Converter Interface Harness (W31) Component Location
Data Converter Interface Harness (W31) Wiring Diagram
2-Speed Harness (W32) Component Location
2-Speed Harness (W32) Wiring Diagram
Heater and Air Conditioner Harness (W41) Component Location
Heater and Air Conditioner Harness (W41) Wiring Diagram
Auxiliary Solenoid Harness (W61) Component Location
Auxiliary Solenoid Harness (W61) Wiring Diagram
Rear Cab Light Switch Harness (W84) Component Location
Rear Cab Light Switch Harness (W84) Wiring Diagram
Rear Cab Light Relay Harness (W85) Component Location
Rear Cab Light Relay Harness (W85) Wiring Diagram
Rear Cab Light Harness (W86) Component Location
Rear Cab Light Harness (W86) Wiring Diagram
Fuel Tank Overflow Shutoff Switch Harness (W89) Component Location-If Equipped
Fuel Tank Overflow Shutoff Switch Harness (W89) Wiring Diagram-If Equipped
Satellite (SAT) Harness (W6003) Component Location
Satellite (SAT) Harness (W6003) Wiring Diagram
JDLinkâ„¢ Harness (W6004) Component Location
JDLinkâ„¢ Harness (W6004) Wiring Diagram
Sub-System Diagnostics
Controller Area Network (CAN) Theory of Operation
Starting and Charging Circuit Theory of Operation
Monitor Controller (DSZ) Circuit Theory of Operation
Engine Controller (ECF) Circuit Theory of Operation
Main Controller (MCZ) Circuit Theory of Operation
Travel Alarm Circuit Theory of Operation
Machine Controller (BCZ) Circuit Theory of Operation
Windshield Wiper and Washer Circuit Theory of Operation
Lighting Circuit Theory of Operation
Pilot Shutoff Circuit Theory of Operation
Attachment Control Circuit Theory of Operation
Monitor Operation
Service Menu
Troubleshooting
Monitoring
Controller Version
Issued Warning Record
Operation
Machine Setting
Monitor Setting
Alarm Setting
Maintenance Mode
Rear View Camera Troubleshooting
References
Reading Diagnostic Trouble Codes with Monitor Display
Service ADVISORâ„¢ Diagnostic Application
Service ADVISORâ„¢ Connection Procedure
Reading Diagnostic Trouble Codes with Service ADVISORâ„¢ Diagnostic Application
Clearing Engine Diagnostic Trouble Codes
MPDr Application
MPDr Connection Procedure
Fuse Test
Relay Test
Pressure Sensor Test
Solenoid Test
Temperature Sensor Test
Alternator Test
Controller Area Network (CAN) Circuit Test
Electrical Component Checks
Battery Remove and Install
Rear Cover Remove and Install
Main Controller (MCZ) Remove and Install
Machine Controller (BCZ) Remove and Install
Engine Controller (ECF) Remove and Install
Data Converter Remove and Install
Monitor Controller (DSZ) Remove and Install
Air Conditioner Controller (ACF) Remove and Install
Key Switch Remove and Install
Right Switch Console Remove and Install
Left Switch Console Remove and Install
Travel Alarm Remove and Install
Disconnect Tab Retainer Connectors
Disconnecting Spring Wire Clip Connectors
Replace DEUTSCHâ„¢ Connectors
Replace DEUTSCHâ„¢ Rectangular or Triangular Connectors
Install DEUTSCHâ„¢ Contact
Replace WEATHER PACKâ„¢ Connector
Install WEATHER PACKâ„¢ Contact
Replace (Pull Type) Metri-Packâ„¢ Connectors
Replace (Push Type) Metri-Packâ„¢ Connectors
Replace CINCHâ„¢ Connectors
Install CINCHâ„¢ Contact
Repair 32 and 48 Way CINCHâ„¢ Connectors
Remove Connector Body from Blade Terminals
Power Train
Theory of Operation
Track Adjuster and Recoil Spring Operation
Travel Gear Case Operation
Diagnostic Information
Noisy or Loose Track Chain
Tight Track Chain
Frequent Track Chain Sag Adjustment Required
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
Bent Track Shoes
“Popping” of Track
Cracked Track Link
Chipped Link Rails
Individual Undercarriage Component Wear
Measure Swing Bearing Wear
Hydraulic System
Theory of Operation
Hydraulic System Operation
Pilot System Operation
Pilot Pump, Pressure Regulating Valve, and Filter Operation
Pilot Shutoff Solenoid Valve Operation
Pilot Control Valve Operation
Travel Pilot Control Valve Operation
Pilot Operation of Control Valve Operation
Pilot Signal Manifold Operation
Pump 1, Pump 2, and Drive Gear Case Operation
Pump 1 and Pump 2 Regulator Operation
Engine Speed Sensing Control Circuit Operation
Control Valve Operation
Control Valve Check Valves Identification and Operation
Main Relief Valve Circuit Operation
Circuit Relief and Anticavitation Valve Operation
Travel Flow Combiner Valve Operation
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation
Boom Lower Meter-In Cut Valve Operation
Boom Regenerative Valve Circuit Operation
Dig Regenerative Valve Circuit Operation
Arm Regenerative Valve Circuit Operation
Bucket Regenerative Valve Circuit Operation
Boom and Arm Reduced Leakage Valves Operation
Arm 1 Flow Rate Control Valve Circuit Operation
Arm 2 Flow Rate Control Valve Circuit Operation
Bucket Flow Rate Control Valve Circuit Operation
Boom Flow Rate Control Valve Circuit Operation
Auxiliary Flow Rate Control Valve Circuit Operation
Swing Reduction Gear Case Operation
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation
Swing Motor Damper Valve
Swing Motor Park Brake Release Circuit Operation
Center Joint Operation
Travel Motor and Park Brake Valve Operation
Travel Motor Speed Circuit Operation
Cylinder Operation
Return Filter Operation
Auxiliary System Operation
Auxiliary Pilot Control Valve Operation
Flow Rate Select Solenoid Valve Operation
Flow Rate Pressure Reducing Valve Operation
Secondary Auxiliary Relief Valve Solenoid Valve Operation
Secondary Auxiliary Relief Control Valve Operation
Secondary Auxiliary Relief Valve Operation
Selector Valve Solenoid Valve Operation
Selector Valve Operation
Auxiliary Shuttle Valve Operation
Auxiliary High Flow Line Kit Operation
Two Way Solenoid Kit Operation
Two Pump Combined Flow Kit Operation
Secondary Auxiliary Relief Kit Operation
Low Flow Kit Operation
Diagnostic Information
All Hydraulic Functions Slow
Hydraulic Oil Overheats
No Hydraulic Functions
Poor Combined Operation
All Functions Cannot Be Operated
Function Does Not Stop When Control Lever Released
Some Functions Cannot Be Operated, All Others Are Normal
All Functions Slow
Functions Move in Opposite Direction
All Dig Functions Slow or No Power
Some Dig Functions Slow (Not All)
Load Drifts Down When Control Lever is in Neutral Position
Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal
Swing Speed Slow in Both Directions
Swing Speed Slow or Does Not Operate in One Direction
Upperstructure Drift With Swing Valve in Neutral
Swing Function Does Not Operate
Travel Park Brakes Do Not Apply
Track Will Not Move in One Direction
Track Will Not Move in Either Direction
Machine Mistracks at All Speeds in Both Directions
Slow Travel Speed or Low Power
Combined Travel and Dig Functions Slow or No Power
Travel is “Jerky”
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs
Pump 1, Pump 2, and Pilot Pump Line Identification
Control Valve Line Identification
Swing Motor Line Identification
Pilot Control Valve-to-Pilot Signal Manifold Component Location-Excavator Pattern
Pilot Control Valve-to-Pilot Signal Manifold Component Location-Backhoe Pattern
Pilot Signal Manifold-to-Control Valve Line Connection
Travel System Component Location
Travel Hydraulic System Line Connection
Auxiliary Attachment Schematic
Auxiliary System Line Connections
Hydraulic System Schematic
Hydraulic System Component Location
Hydraulic System Line Connections
Tests
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure and Temperature Analyzer Kit Installation
General Hydraulic Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Hydraulic Oil Tank Pressure Release Procedure
Hydraulic Oil Warm-Up Procedure
Pilot Pressure Regulating Valve Test and Adjustment
Control Valve Spool Actuating Pilot Pressure Test
Dig Regenerative Solenoid Valve Test and Adjustment
Arm Regenerative Solenoid Valve Test and Adjustment
Power Dig Solenoid Valve Test and Adjustment
Torque Control Solenoid Valve Test and Adjustment
Pump Control Pilot Pressure Signal Test
Main Relief and Power Dig Valve Test and Adjustment
Circuit Relief Valve Test and Adjustment
Swing Motor Crossover Relief Valve Test and Adjustment
Travel Motor Crossover Relief Valve Test and Adjustment
Pump Regulator Test and Adjustment-Minimum Flow
Pump Regulator Test and Adjustment-Maximum Flow
Pump Flow Test
Comprehensive Pump Flow Test
Swing Motor Leakage Test
Travel Motor Leakage Test
Cylinder Drift Test-Boom, Arm, and Bucket
Heating and Air Conditioning
Theory of Operation
Air Conditioning System Cycle of Operation
Diagnostic Information
No Air Flow From Heater and Air Conditioner Vents
Air Conditioning System Does Not Operate
Air Conditioning Does Not Cool Interior of Cab
Air Conditioning Runs Constantly, Too Cold
Interior Windows Continue to Fog Using Air Conditioner
Heater System Does Not Operate
Heater Does Not Warm Interior of Cab
Interior Windows Continue to Fog Using Heater
Heater and Air Conditioner Component Location
Tests
Refrigerant Cautions and Proper Handling
Heater and Air Conditioner Operational Checks
Air Conditioner Compressor Clutch Test
Refrigerant Leak Test
Refrigerant Hoses and Tubing Inspection
Air Conditioner Compressor Belt Check
Air Conditioner High/Low-Pressure Switch Test
Air Conditioner Freeze Control Switch Test
R134a Air Conditioning System Test
Operating Pressure Diagnostic Chart
Dealer Fabricated Tools
Dealer Fabricated Tools
DFT1218 Split Flange Hose Cap