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Hitachi ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual
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Hitachi Hybrid Excavator ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual
Size: 108.18 MB
Format: PDF
Language: English
Brand: Hitachi
Type of Machine: Hybrid Excavator
Type of Manual: Technical Manual, Troubleshooting, Operational Principle, Electrical and Hydraulic Circuit Diagram
Model: Hitachi ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Hybrid Excavator
List of Files:
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical and Hydraulic Circuit Diagram TTDFX50-EN-00.pdf (Pages: 17)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical Circuit Diagram SIDE VIEW CAMERA.pdf (Pages: 3)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00.pdf (Pages: 666)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Operational Principle TODFX50-EN-00.pdf (Pages: 535)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20180713).pdf (Pages: 670)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20201102).pdf (Pages: 670)
Detail Content:
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical and Hydraulic Circuit Diagram TTDFX50-EN-00.pdf
ELECTRICAL CIRCUIT DIAGRAM
CONNECTORS
CAB HARNESS
ENGINE HARNESS
PUMP HARNESS
CONTROL VALVE 1 SUB HARNESS
CONTROL VALVE 2 SUB HARNESS
RADIATOR SUB HARNESS
MONITOR HARNESS
MUFFLER FILTER REGENERATION SWITCH HARNESS
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS
SATELLITE COMMUNICATION HARNESS
KEY SWITCH HARNESS
PILOT SHUT-OFF SOLENOID VALVE HARNESS
REARVIEW CAMERA HARNESS
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM) (OPTIONAL)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical Circuit Diagram SIDE VIEW CAMERA.pdf
ZX-6_ELE_SIDEVIEW-CAMERA_EN
ZX-6_STD_CAB_SIDEVIEW-CAMERA_EN
ZX-6_STD_MAIN_SIDEVIEW-CAMERA_EN
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00.pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Operational Principle TODFX50-EN-00.pdf
TODFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
SYMBOL AND ABBREVIATION
SECTION AND GROUP CONTENTS
SECTION 1 GENERAL
Group 1 Specifications
Specifications
Working Ranges (Grouser shoe)
Group 2 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Around Air Cleaner
Around Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Around Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-spool solenoid valve unit
Layout of Attachment Spec. Parts
Breaker Related Component
Group 3 Component Specifications
Engine
Engine Accessories
Hydraulic Component
Electrical Component
Hybrid Related Component
Hybrid System Cooling Component
SECTION 2 SYSTEM
Group 1 Controller
Outline
CAN Circuit
Group 2 Control System
Outline
Engine Control
Pump Control
Valve Control (Standard)
Valve Control (Option)
Pump/Valve Combination Control
Other Control
Group 3 Engine System
Outline
Fuel Injection Control
Fuel Injection Amount Correction Control
EGR Control
Engine Output Restriction Control (INDUCEMENT)
Preheating Control
Variable Turbocharger Control
Alarm Control
Muffler Filter Control
Group 4 Hydraulic System
Outline
Pilot Circuit
Main Circuit
Breaker/Pulverizer/Crusher Circuit (Option)
Group 5 Electrical System
Outline
Main Circuit
Electric Power Circuit (Key Switch: OFF)
CAN Circuit
Accessory Related Circuit (Key Switch: ACC)
Starting Circuit (Key Switch: START)
Engine Start Assist Circuit
Charging Circuit (Key Switch: ON)
Surge Voltage Prevention Circuit
Pilot Shut-Off Circuit (Key Switch: ON)
Auto Shut-Down Standby Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature
Engine Stop Circuit
Monitor Circuit
Security Circuit
Radio Circuit
Air Conditioner Circuit
Accessory Circuit
Work Light Circuit
Wiper/Washer Circuit
Cab Light Circuit
Group 6 Hybrid System
Outline
Energy Management Control
Power Management Control
Engine Assist Control
Hybrid System Activation/Braking Torque Limit Control
Swing Control
Lithium-ion Battery Temperature Control
Cooling/Warm-up circuit of Lithium-ion Battery
Cooling circuit of swing electric motor, PCU-A, PCU-S
Power Electrical Circuit for Electric Components
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Outline
Main Pump
Regulator
Solenoid Valve
Pilot Pump
Pump Delivery Pressure Sensor
Pump Control Pressure Sensor
Group 2 Swing Device
Swing Device
Swing Reduction Gear
Swing Hydraulic Motor
Swing Parking Brake
Valve Unit
Swing Low-pressure relief valve Unit
Swing Electric Motor
Group 3 Control Valve
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Valve
Overload Relief Valve (with Make-Up Function)
Regenerative Valve
Anti-Drift Valve
Flow Rate Control Valve
Digging Regenerative Valve
Boom Lower Meter-In Cut Valve
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve
Group 4 Pilot Valve
Outline
Operation (Front Attachment/Swing and Travel Pilot Valves)
Operation (Auxiliary Pilot Valve)
Shockless Function (Only for Travel Pilot Valve)
Group 5 Travel Device
Outline
Travel Reduction Gear
Travel Motor
Parking Brake
Travel Brake Valve
Overload Relief Valve
Travel Mode Control
Group 6 Signal Control Valve
Outline
Pilot Port
Shuttle Valve
Shockless Valve
Pump 1 Flow Rate Control Valve, Pump 2 Flow Rate Control Valve, Pump 3 Flow Rate Control Valve
Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool
Group 7 Others (Upperstructure)
Pilot Shut-Off Solenoid Valve
Solenoid Valve
Pilot Relief Valve
Recirculation Valve
Group 8 Others (Undercarriage)
Swing Bearing
Centerjoint
Track Adjuster (Front Idler Integrated Type)
Group 9 Assist Alternator Motor
Assist Alternator Motor
SERVICE MANUAL REVISION REQUEST FORM
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20180713).pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20201102).pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
Size: 108.18 MB
Format: PDF
Language: English
Brand: Hitachi
Type of Machine: Hybrid Excavator
Type of Manual: Technical Manual, Troubleshooting, Operational Principle, Electrical and Hydraulic Circuit Diagram
Model: Hitachi ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Hybrid Excavator
List of Files:
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical and Hydraulic Circuit Diagram TTDFX50-EN-00.pdf (Pages: 17)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical Circuit Diagram SIDE VIEW CAMERA.pdf (Pages: 3)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00.pdf (Pages: 666)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Operational Principle TODFX50-EN-00.pdf (Pages: 535)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20180713).pdf (Pages: 670)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20201102).pdf (Pages: 670)
Detail Content:
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical and Hydraulic Circuit Diagram TTDFX50-EN-00.pdf
ELECTRICAL CIRCUIT DIAGRAM
CONNECTORS
CAB HARNESS
ENGINE HARNESS
PUMP HARNESS
CONTROL VALVE 1 SUB HARNESS
CONTROL VALVE 2 SUB HARNESS
RADIATOR SUB HARNESS
MONITOR HARNESS
MUFFLER FILTER REGENERATION SWITCH HARNESS
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS
SATELLITE COMMUNICATION HARNESS
KEY SWITCH HARNESS
PILOT SHUT-OFF SOLENOID VALVE HARNESS
REARVIEW CAMERA HARNESS
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM) (OPTIONAL)
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Electrical Circuit Diagram SIDE VIEW CAMERA.pdf
ZX-6_ELE_SIDEVIEW-CAMERA_EN
ZX-6_STD_CAB_SIDEVIEW-CAMERA_EN
ZX-6_STD_MAIN_SIDEVIEW-CAMERA_EN
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00.pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Operational Principle TODFX50-EN-00.pdf
TODFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
SYMBOL AND ABBREVIATION
SECTION AND GROUP CONTENTS
SECTION 1 GENERAL
Group 1 Specifications
Specifications
Working Ranges (Grouser shoe)
Group 2 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Around Air Cleaner
Around Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Around Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-spool solenoid valve unit
Layout of Attachment Spec. Parts
Breaker Related Component
Group 3 Component Specifications
Engine
Engine Accessories
Hydraulic Component
Electrical Component
Hybrid Related Component
Hybrid System Cooling Component
SECTION 2 SYSTEM
Group 1 Controller
Outline
CAN Circuit
Group 2 Control System
Outline
Engine Control
Pump Control
Valve Control (Standard)
Valve Control (Option)
Pump/Valve Combination Control
Other Control
Group 3 Engine System
Outline
Fuel Injection Control
Fuel Injection Amount Correction Control
EGR Control
Engine Output Restriction Control (INDUCEMENT)
Preheating Control
Variable Turbocharger Control
Alarm Control
Muffler Filter Control
Group 4 Hydraulic System
Outline
Pilot Circuit
Main Circuit
Breaker/Pulverizer/Crusher Circuit (Option)
Group 5 Electrical System
Outline
Main Circuit
Electric Power Circuit (Key Switch: OFF)
CAN Circuit
Accessory Related Circuit (Key Switch: ACC)
Starting Circuit (Key Switch: START)
Engine Start Assist Circuit
Charging Circuit (Key Switch: ON)
Surge Voltage Prevention Circuit
Pilot Shut-Off Circuit (Key Switch: ON)
Auto Shut-Down Standby Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature
Engine Stop Circuit
Monitor Circuit
Security Circuit
Radio Circuit
Air Conditioner Circuit
Accessory Circuit
Work Light Circuit
Wiper/Washer Circuit
Cab Light Circuit
Group 6 Hybrid System
Outline
Energy Management Control
Power Management Control
Engine Assist Control
Hybrid System Activation/Braking Torque Limit Control
Swing Control
Lithium-ion Battery Temperature Control
Cooling/Warm-up circuit of Lithium-ion Battery
Cooling circuit of swing electric motor, PCU-A, PCU-S
Power Electrical Circuit for Electric Components
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Outline
Main Pump
Regulator
Solenoid Valve
Pilot Pump
Pump Delivery Pressure Sensor
Pump Control Pressure Sensor
Group 2 Swing Device
Swing Device
Swing Reduction Gear
Swing Hydraulic Motor
Swing Parking Brake
Valve Unit
Swing Low-pressure relief valve Unit
Swing Electric Motor
Group 3 Control Valve
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Valve
Overload Relief Valve (with Make-Up Function)
Regenerative Valve
Anti-Drift Valve
Flow Rate Control Valve
Digging Regenerative Valve
Boom Lower Meter-In Cut Valve
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve
Group 4 Pilot Valve
Outline
Operation (Front Attachment/Swing and Travel Pilot Valves)
Operation (Auxiliary Pilot Valve)
Shockless Function (Only for Travel Pilot Valve)
Group 5 Travel Device
Outline
Travel Reduction Gear
Travel Motor
Parking Brake
Travel Brake Valve
Overload Relief Valve
Travel Mode Control
Group 6 Signal Control Valve
Outline
Pilot Port
Shuttle Valve
Shockless Valve
Pump 1 Flow Rate Control Valve, Pump 2 Flow Rate Control Valve, Pump 3 Flow Rate Control Valve
Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool
Group 7 Others (Upperstructure)
Pilot Shut-Off Solenoid Valve
Solenoid Valve
Pilot Relief Valve
Recirculation Valve
Group 8 Others (Undercarriage)
Swing Bearing
Centerjoint
Track Adjuster (Front Idler Integrated Type)
Group 9 Assist Alternator Motor
Assist Alternator Motor
SERVICE MANUAL REVISION REQUEST FORM
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20180713).pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
ZH200-6 ZX200LC-6 ZH210-6 ZX210LC-6 Technical Manual Troubleshooting TTDFX50-EN-00(20201102).pdf
TTDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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 the 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 People Clear from Working Area
Never Position the 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
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 Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
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 (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
3-Spool Solenoid Valve Set Pressure
2-Spool Solenoid Valve (for Swing Relief Control) Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
RELIEF PRESSURE (Relief operation of Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Pump Learning
No-Load-Max Differential Pressure Measuring Method
Group 7 Hybrid Component Performance Test
Relief Pressure (When Relieving Swing)
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
Check the alternator.
Continuity check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
How to Use Inspection Equipment
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
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Electrical System (Rear Tray)
Electrical System (Switch Panel)
Components Related with Air Cleaner
Components Related with Battery
Engine
Lithium-ion Battery Unit
Muffler Filter
Pump Device
Components Related with Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
5-Spool Solenoid Valve Unit
Swing Control Solenoid Valve Unit/3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Components Related with Breaker
Components in Control Valve
Pilot Port
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
MC Fault Code List
ECU 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, 11486
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
MC Fault Code 11101
MC Fault Codes 11200 to 11202
MC Fault Code 11203
MC Fault Codes 11206 to 11208
MC Fault Codes 11302 to 11303
MC Fault Codes 11304, 11307, 11325
MC Fault Codes 11995, 11997, 11998
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 Codes 11434, 11435
MC Fault Code 11436
MC Fault Codes 11458, 11459
MC Fault Codes 11802, 11470
MC Fault Codes 11471 to 11472
MC Fault Codes 11473 to 11474
MC Fault Code 11475
MC Fault Code 11477
MC Fault Code 11478
MC Fault Code 11479
MC Fault Code 11480
MC Fault Code 11481
MC Fault Code 11483
MC Fault Code 11484
MC Fault Code 11485
MC Fault Code 11901
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
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lower Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lower Boom When Emergency and When Engine Stops with Hose Rupture Valve
Attachment Circuit Pressure Release Procedure
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
Group 8 Hybrid Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Abnormality Control List
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 19511
HCU Fault Code 19512
HCU Fault Code 19513
Check the HCU harness.
HCU Fault Codes 19550, 19552 to 19555, 19561
CAN0 Harness Check
INV-CAN Harness Check
HCU Fault Codes 19556 to 19560, and 19563
Check the wire harness between HCU and the lithium-ion battery unit.
HCU Fault Code 19564
Check the wire harness between HCU or ECU and the engine stop switch.
HCU Fault Code 19565
HCU Fault Code 19568
Wire Harness Check between HCU and Water Cooling Pump
HCU Fault Codes 19569, 19570
Check the wire harness between PCU-A or PCU-S and the PCU-A cut relay or the PCU-S cut relay.
Check the wire harness between the pilot shut-off switch and the PCU-S cut relay.
HCU Fault Code 19571
HCU Fault Code 15011
HCU Fault Codes 15016, 15017, 15019
HCU Fault Codes 15028, 15029
HCU Fault Code 19580
HCU Fault Code 19581
HCU Fault Code 19582
HCU Fault Code 19582
HCU Fault Codes 19586, 19587
HCU Fault Code 19584
Check the insulated state of the power harness between the assist alternator motor and PCU-A, and check the insulated state of PCU-A.
Insulation Check of Power Harness Between Assist Alternator Motor and PCU-S, Insulation Check of PCU-S
PCU-A Fault Code List
Check for Power Harness Between Assist Alternator Motor and PCU-A, Check for Assist Alternator Motor
Check for Wire Harness Between Assist Alternator Motor (Resolver) and PCU-A, Check for Assist Alternator Motor (Resolver)
Check for Wire Harness Between Assist Alternator Motor (Thermistor) and PCU-A, Check for Assist Alternator Motor (Thermistor)
INV-CAN Harness Check
PCU-A Fault Code 19700
PCU-A Fault Code 19701
PCU-A Fault Code 19702
PCU-A Fault Code 19703
PCU-A Fault Code 19704
PCU-A Fault Code 19705
PCU-A Fault Code 19706
PCU-A Fault Codes 19707 to 19710
PCU-A Fault Codes 19711 to 19713, 19717
PCU-A Fault Code 19715
PCU-A Fault Code 19716
PCU-A Fault Code 19718
PCU-A Fault Code 19719
PCU-A Fault Codes 19720, 19721
PCU-A Fault Codes 19722 to 19724
PCU-S Fault Code List
Check for Power Harness Between Swing Electric Motor and PCU-S, Check for Swing Electric Motor
Check for Wire Harness Between Swing Electric Motor (Resolver) and PCU-S, Check for Swing Electric Motor (Resolver)
Check for Wire Harness Between Swing Electric Motor (Thermistor) and PCU-S, Check for Swing Electric Motor (Thermistor)
INV-CAN Harness Check
PCU-S Fault Code 19730
PCU-S Fault Code 19731
PCU-S Fault Code 19732
PCU-S Fault Code 19733
PCU-S Fault Code 19734
PCU-S Fault Code 19735
PCU-S Fault Code 19736
PCU-S Fault Codes 19737 to 19740
PCU-S Fault Codes 19741 to 19743, 19747
PCU-S Fault Code 19745
PCU-S Fault Code 19746
PCU-S Fault Code 19748
PCU-S Fault Code 19749
PCU-S Fault Codes 19750, 19751
PCU-S Fault Codes 19752 to 19754
BCU Fault Code List
Fault codes of BCU19764, 19766 to 19775, 19782, 19783, 19785 to 19787, 19789 to 19791
BCU Fault Code 19763
BCU Fault Code 19762
BCU Fault Code 19761
BCU Fault Code 19760
BCU Fault Code 19788
BCU Fault Code 19765
BCU Fault Codes 19776, 19777, 19779 to 19781
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
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