Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00) – PDF Download
Original price was: $66.95.$25.95Current price is: $25.95.
- Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual
- Part No:TT4FK-E-00
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00)
File Details:
Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00)
- Manual Language:English
- Pages: 424
- Size: 4.21 MB
- Format:PDF
- Downloadable:Yes
HITACHI ZW100-G ZW120-G WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TT4FK-E-00) – PDF DOWNLOAD:
Image Preview:
Description:
Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00)
TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.
Table Of Contents:
Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00)
TT4FL-E-00................................................................................................................. 1 INTRODUCTION............................................................................................................... 3 SAFETY..................................................................................................................... 5 SECTION AND GROUP CONTENTS................................................................................................. 35 SECTION 4 OPERATIONAL PERFORMANCE TEST ................................................................................... 37 Group 1 Introduction................................................................................................... 39 Operational Performance Tests...................................................................................... 39 Preparation for Performance Tests.................................................................................. 40 Group 2 Standard....................................................................................................... 41 ZW100-G Operational Performance Standard Table..................................................................... 41 ZW120-G Operational Performance Standard Table..................................................................... 45 Sensor Activating Range............................................................................................ 49 Group 3 Engine Test.................................................................................................... 51 Engine Speed....................................................................................................... 51 Engine Compression Pressure........................................................................................ 53 Valve Clearance.................................................................................................... 54 Group 4 Wheel Loader Test.............................................................................................. 57 Travel Speed....................................................................................................... 57 Service Brake Capacity............................................................................................. 58 Parking Brake Capacity............................................................................................. 59 Hydraulic Cylinder Cycle Time...................................................................................... 60 Dig Function Drift................................................................................................. 62 Control Lever Operating Force...................................................................................... 63 Control Lever and Pedal Stroke..................................................................................... 64 Group 5 Component Test................................................................................................. 65 Main Pump Delivery Pressure........................................................................................ 65 HST Pump Delivery Pressure (HST Pump Relief Pressure).............................................................. 66 HST Charge Pump Delivery Pressure.................................................................................. 69 Transmission Charge Pump Delivery Pressure......................................................................... 70 Main Relief Valve Pressure......................................................................................... 72 HST Charge Relief Pressure......................................................................................... 74 Overload Relief Pressure........................................................................................... 76 Steering Relief Pressure........................................................................................... 78 HST Pump Displacement angle Control Pressure....................................................................... 80 HST Motor Displacement angle Control Pressure...................................................................... 83 Transmission Clutch Pressure....................................................................................... 84 SECTION 5 TROUBLESHOOTING ................................................................................................ 89 Group 1 Diagnosing Procedure........................................................................................... 93 Introduction....................................................................................................... 93 Diagnosing Procedure............................................................................................... 94 How to Operate Service Mode of Monitor Panel....................................................................... 98 Display List of Monitor Service Mode............................................................................... 99 Group 2 Dr.ZX..........................................................................................................101 Outline............................................................................................................101 Operation..........................................................................................................102 Self-Diagnostic Result.............................................................................................104 Select Controller..................................................................................................106 Main Controller....................................................................................................107 Main Menu Monitor Display..........................................................................................108 Setting............................................................................................................112 Recorded Data Display..............................................................................................115 Password Change....................................................................................................116 Engine Controller..................................................................................................117 Main Menu Monitor Display..........................................................................................118 Recorded Data Display..............................................................................................122 Password Change....................................................................................................123 ICF Controller.....................................................................................................125 Information C/U Various Setup......................................................................................126 Save Data Check....................................................................................................136 Password Change....................................................................................................137 Monitor Unit.......................................................................................................139 Monitoring.........................................................................................................140 Various Settings...................................................................................................142 Internal Hour Meter Synchronization................................................................................143 Password Change....................................................................................................144 Group 3 e-Wheel........................................................................................................145 Outline............................................................................................................145 List of Daily Report Data..........................................................................................146 List of Frequency Distribution Data................................................................................147 List of Total Operating Hours......................................................................................148 List of Alarm......................................................................................................149 How to Download and Upload Data of ICF.............................................................................150 Various Setup of ICF and Satellite Communication Terminal by Using Dr.ZX...........................................153 List of Fault Code.................................................................................................165 Satellite Communication System.....................................................................................166 Group 4 Component Layout...............................................................................................169 Main Component Layout (Upperstructure).............................................................................169 Main Component Layout (Travel System)..............................................................................170 Electrical System (Overview).......................................................................................171 Electrical System (Relay and Others)...............................................................................172 Electrical System (In Canopy)......................................................................................173 Electrical System (In Cab).........................................................................................174 Electrical System (Relays).........................................................................................175 Front Console (In Canopy)..........................................................................................176 Front Console (In Cab).............................................................................................177 Monitor Panel......................................................................................................178 Engine.............................................................................................................179 Pump Device........................................................................................................180 Transmission.......................................................................................................181 Control Valve/Priority Valve.......................................................................................182 Group 5 Troubleshooting A..............................................................................................187 Troubleshooting A Procedure........................................................................................187 Fault Code List....................................................................................................188 Controller Hardware Failure MC Fault Code 11004....................................................................203 CAN Harness Check..................................................................................................204 MC Fault Code 11330................................................................................................223 MC Fault Code 11331................................................................................................224 MC Fault Code 11332................................................................................................225 MC Fault Code 11430................................................................................................226 MC Fault Code 11433................................................................................................227 MC Fault Code 11450................................................................................................228 MC Fault Code 11451................................................................................................229 MC Fault Code 11452................................................................................................230 MC Fault Code 11455................................................................................................231 MC Fault Code 11456................................................................................................232 MC Fault Code 11622................................................................................................233 MC Fault Code 11904................................................................................................234 MC Fault Code 11801................................................................................................235 Can Data Reception Failure MC Fault Codes 11910....................................................................236 Can Harness Check Fault Code 11910.................................................................................238 MC Fault Code 11914................................................................................................240 Can Harness Check Fault Code 11914.................................................................................242 ECM Fault Codes 100, 110, 168, 190, 628, 1077, 1485, 10007, 10018, 10024...........................................244 ECM Fault Codes 10027 to 10034.....................................................................................245 ICF, Satellite Terminal Fault Codes 14000 to 14003.................................................................246 ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14107...................................................250 Monitor Unit Fault Code 13304......................................................................................252 Monitor Unit Fault Codes 13306, 13308..............................................................................253 Monitor Unit Fault Code 13310......................................................................................254 Monitor Unit Fault Code 13311......................................................................................255 Monitor Unit Fault Code 13315......................................................................................256 Monitor Unit Fault Code 13319......................................................................................257 Fault Detection of Proportional Solenoid Valve.....................................................................258 Group 6 Troubleshooting B..............................................................................................261 Troubleshooting B Procedure........................................................................................261 Relationship between Machine Trouble Symptoms and Related Parts....................................................262 Correlation between Trouble Symptoms and Part Failures.............................................................272 Engine System Troubleshooting......................................................................................280 Front Attachment System Troubleshooting............................................................................289 Travel System Troubleshooting......................................................................................299 Brake System Troubleshooting.......................................................................................312 Steering System Troubleshooting....................................................................................319 Other System Troubleshooting.......................................................................................321 Releasing Parking Brake in Case of Emergency and when Engine Stops.................................................343 Recovery of Released Parking Brake.................................................................................344 One Part of Data, “Daily Report Data”, “Distribution Data”, “Total Operating Hours” and “Alarm” is Not Recorded....346 Group 7 Troubleshooting C..............................................................................................361 Troubleshooting C (Trouble Shooting for Monitor Panel) Procedure...................................................361 Malfunction of Indicator Light Check System........................................................................362 Malfunction of Buzzer in Monitor Panel.............................................................................364 Malfunction of Coolant Temperature Gauge...........................................................................366 Malfunction of HST Oil Temperature Gauge...........................................................................368 Malfunction of Fuel Gauge..........................................................................................370 Malfunction of Turn Signal Indicators (Left and Right).............................................................372 Malfunction of Hazard Light Indicator..............................................................................373 Malfunction of High Beam Indicator.................................................................................374 Malfunction of Working Light Indicator.............................................................................376 Malfunction of Maintenance Indicator...............................................................................378 Malfunction of Preheat Indicator...................................................................................379 Malfunction of HST Oil Temperature Indicator.......................................................................380 Malfunction of HST Warning Indicator...............................................................................382 Malfunction of Engine Oil Pressure Indicator.......................................................................384 Faulty Overheat Indicator..........................................................................................385 Malfunction of Engine Warning Indicator............................................................................386 Malfunction of Stop Indicator......................................................................................387 Malfunction of Service Indicator...................................................................................388 Malfunction of Parking Brake Indicator.............................................................................390 Malfunction of Clearance Light Indicator...........................................................................392 Malfunction of Brake Low Oil Level Indicator.......................................................................394 Malfunction of Emergency Steering Indicator (Optional).............................................................396 Malfunction of Low Steering Oil Pressure Indicator (Optional)......................................................398 Malfunction of Discharge Warning Indicator.........................................................................400 Malfunction of Monitor Display.....................................................................................402 Malfunction of Ride Control Indicator (Optional)...................................................................403 Malfunction of Engine Coolant Temperature Display..................................................................404 Group 8 Electrical System Inspection...................................................................................405 Precautions for Inspection and Maintenance........................................................................405 Instructions for Disconnecting Connectors..........................................................................407 Fuse Inspection....................................................................................................408 Fusible Link and Fuse (100A) Inspection............................................................................410 Battery Voltage Check..............................................................................................411 Alternator Check...................................................................................................412 Continuity Check...................................................................................................413 Voltage and Current Measurement....................................................................................414 Check by False Signal..............................................................................................419 SERVICE MANUAL REVISION REQUEST FORM ......................................................................................423 THE ATTACHED DIAGRAM LIST .................................................................................................424
Please Note:
⦁ This is the SAME MANUAL used by the dealerships to diagnose your vehicle
⦁ No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
⦁ Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
⦁ So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
