Hitachi ZW120-5B Wheel Loader Troubleshooting Technical Manual (TTNCC-EN-00) – PDF Download

Description

Hitachi ZW120-5B Wheel Loader Troubleshooting Technical Manual (TTNCC-EN-00)

File Details:

Hitachi ZW120-5B Wheel Loader Troubleshooting Technical Manual (TTNCC-EN-00)

• Manual Language:English
• Pages: 404
• Size: 4.63 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZW120-5B WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTNCC-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW120-5B Wheel Loader Troubleshooting Technical Manual (TTNCC-EN-00)

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
 Information included in the Technical Manual:Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
 Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Contents:

Hitachi ZW120-5B Wheel Loader Troubleshooting Technical Manual (TTNCC-EN-00)

TTNCC-EN-00.................................................................................  1
INTRODUCTION................................................................................  3
SYMBOL AND ABBREVIATION.....................................................................  5
SAFETY......................................................................................  7
SECTION AND GROUP CONTENTS.................................................................. 47
SECTION 4 OPERATIONAL PERFORMANCE TEST...................................................... 49
	Group 1 Introduction.................................................................... 51
		Operational Performance Tests....................................................... 51
		Preparation for Performance Tests................................................... 52
	Group 2 Standard........................................................................ 53
		Operational Performance Standard Table.............................................. 53
		Sensor Activating Range............................................................. 60
	Group 3 Engine Test..................................................................... 61
		Engine Speed........................................................................ 61
		Lubricant Consumption............................................................... 63
	Group 4 Machine Performance Test........................................................ 65
		Travel Speed........................................................................ 65
		Service Brake Function Check........................................................ 68
		Service Brake Wear Amount........................................................... 70
		Parking Brake Function Check........................................................ 71
		Bucket Stopper and Bell Crank Stopper Clearance..................................... 72
		Hydraulic Cylinder Cycle Time....................................................... 74
		Dig Function Drift Check............................................................ 76
		Bucket Levelness.................................................................... 77
		Control Lever Operating Force....................................................... 78
		Control Lever Stroke................................................................ 80
	Group 5 Component Test.................................................................. 81
		Main Pump Delivery Pressure......................................................... 81
		HST Pump Delivery Pressure.......................................................... 82
		HST Charging Pump Delivery Pressure(HST Charging Pump Relief Pressure).............. 83
		Brake/ Transmission Pump Delivery Pressure.......................................... 84
		Main Relief Set Pressure............................................................ 86
		HST Pump Relief Pressure............................................................ 88
		Steering Relief Pressure............................................................ 90
		Overload Relief Valve Set Pressure.................................................. 92
		HST Pump Displacement Angle Control Pressure........................................ 95
		HST Motor Displacement Angle Control Pressure....................................... 97
		Transmission Clutch Pressure........................................................ 99
		Primary Pilot Pressure (Hydraulic Operated Type: Optional)..........................101
		Secondary Pilot Pressure (Hydraulic Operated Type: Optional)........................103
		Accumulator Gas Pressure............................................................105
		Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (OPT)).......107
SECTION 5 TROUBLESHOOTING...................................................................113
	Group 1 Diagnosing Procedure............................................................115
		Introduction........................................................................115
		Diagnosis Procedure.................................................................116
		Electric System Inspection..........................................................119
		Precautions for Inspection and Maintenance..........................................120
		Instructions for Disconnecting Connectors...........................................122
		Fuse Inspection.....................................................................124
		Fusible Link Inspection.............................................................127
		Battery Voltage Check...............................................................128
		Alternator Check....................................................................129
		Continuity Check....................................................................130
		Voltage and Current Measurement.....................................................132
		Check by False Signal...............................................................137
		Test Harness........................................................................138
	Group 2 Monitor.........................................................................141
		Outline.............................................................................141
		Operating Procedures of Service Menu................................................143
		Coolant Temperature Gauge and HST Oil Temperature Gauge.............................147
		Fuel Gauge..........................................................................148
	Group 3 e-Service.......................................................................149
		Outline.............................................................................149
		List of Operation Data..............................................................150
		Communication System................................................................154
	Group 4 Component Layout................................................................155
		Main Component (Upperstructure).....................................................155
		Main Component (Travel System)......................................................156
		Electrical System (Overview)........................................................157
		Electrical System (Components Related with Relays)..................................158
		Electrical System (Components Related with Engine)..................................158
		Electrical System (Cab).............................................................159
		Engine..............................................................................164
		Pump Device.........................................................................165
		Transmission/ HST Motor.............................................................166
		Control Valve.......................................................................167
		Priority Valve......................................................................168
		Ride Control Valve (Optional).......................................................169
		Emergency Steering Block (Optional).................................................170
		Emergency Steering Pump (Optional)..................................................170
		Pilot Shut-Off Solenoid Valve (Hydraulic Operated Type: Optional)...................171
	Group 5 Troubleshooting A...............................................................173
		Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...........173
		MC Fault Code List..................................................................175
		ICF Fault Code List.................................................................178
		Monitor Controller Fault Code List..................................................179
		Air Conditioner Controller Fault Code List..........................................181
		Communication Terminal Fault Code List..............................................183
		ECM Fault Code List.................................................................185
		MC Fault Codes 111004, 111910, 111914...............................................201
		CAN1 Harness Check..................................................................202
		MC Fault Code 111103................................................................205
		MC Fault Code 111217................................................................206
		MC Fault Codes 111330, 111331.......................................................207
		MC Fault Code 111332................................................................208
		MC Fault Code 111422................................................................209
		MC Fault Code 111430................................................................210
		MC Fault Code 111434................................................................211
		MC Fault Codes 111450, 111451.......................................................212
		MC Fault Code 111455................................................................213
		MC Fault Code 111457................................................................214
		MC Fault Code 111622................................................................215
		MC Fault Code 111801................................................................216
		MC Fault Code 111904................................................................217
		MC Fault Code 111908................................................................218
		MC Fault Code 111922................................................................219
		Monitor Controller Fault Code 115000................................................220
		CAN1 Harness Check..................................................................222
		Monitor Controller Fault Code 115001................................................225
		Monitor Controller Fault Code 115011................................................226
		Monitor Controller Fault Code 115014................................................227
		Monitor Controller Fault Code 115015................................................228
		Monitor Controller Fault Codes 120500 to 120502.....................................229
		Monitor Controller Fault Codes 120506, 120507, 120510, 120512, 120515, 120518.......230
		Air Conditioner Controller Fault Codes E11 to E22...................................231
		Air Conditioner Controller Fault Codes E43 to E92...................................232
	Group 6 Troubleshooting B...............................................................233
		Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....233
		Relationship between Machine Trouble Symptoms and Related Parts.....................235
		Correlation between Trouble Symptoms and Part Failures..............................247
		Engine System Troubleshooting.......................................................267
		Front Attachment System Troubleshooting.............................................271
		Steering System Troubleshooting.....................................................281
		Travel System Troubleshooting.......................................................283
		Brake System Troubleshooting........................................................293
		Other System Troubleshooting........................................................297
		Transporting Wheel Loader (Urgent Situation)........................................319
		How to Release Parking Brake in Case of Emergency and When Engine Stops.............322
		Recovery After Parking Brake Release................................................323
	Group 7 Troubleshooting C...............................................................325
		Troubleshooting C (Monitor Diagnosis) Procedure.....................................325
		Malfunction of Monitor Buzzer.......................................................327
		Malfunction of Coolant Temperature Gauge............................................328
		Malfunction of Fuel Gauge...........................................................329
		Malfunction of HST Oil Temperature Gauge............................................330
		Malfunction of Monitor Display......................................................332
		Malfunction of Light Bulb Check Ststem..............................................334
		Malfunction of Left And Right Turn Signal Light Indicators..........................335
		Malfunction of Hazard Light Indicator...............................................336
		Malfunction of High Beam Indicator..................................................337
		Malfunction of Work Light Indicator.................................................338
		Malfunction of Maintenance Light....................................................340
		Malfunction of Preheat Indicator....................................................341
		Malfunction of HST Oil Temperature Indicator........................................342
		Malfunction of HST Warning Indicator................................................343
		Malfunction of Engine Oil Pressure Indicator........................................344
		Malfunction of Overheat Indicator...................................................345
		Malfunction of Engine Warning Indicator.............................................346
		Malfunction of Service Indicator....................................................347
		Malfunction of Parking Brake Indicator..............................................348
		Malfunction of Clearance Light Indicator............................................349
		Malfunction of Emergency Steering Indicator (OPT)...................................350
		Malfunction of Low Steering Oil Pressure Indicator (OPT)............................351
		Malfunction of Alternator Indicator.................................................352
		Malfunction of Control Lever Lock Indicator (Optional)..............................353
		Malfunction of Power Mode Indicator.................................................353
		Malfunction of Seat Belt Indicator (Optional).......................................354
	Group 8 Air Conditioner.................................................................355
		Outline.............................................................................355
		Functions of Main Parts.............................................................360
		Troubleshooting.....................................................................365
		Air Conditioner Controller Fault Code List..........................................366
		Air Conditioner Controller Fault Codes E11 to E22...................................367
		Air Conditioner Controller Fault Codes E43 to E92...................................368
		Work after Replacing Components.....................................................390
		Refill Compressor Oil...............................................................391
		Charge Air Conditioner with Refrigerant.............................................392
		Hose and Pipe Tightening Torque.....................................................400
SERVICE MANUAL REVISION REQUEST FORM........................................................403
The Attached Diagram List...................................................................404

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