Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00) – PDF Download

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Hitachi ZW100-G ZW120-G Wheel Loader Troubleshooting Technical Manual (TT4FK-E-00)

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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:

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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

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