Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hitachi ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual (TT4GB-E-00) – PDF Download
Original price was: $89.95.$25.95Current price is: $25.95.
- Hitachi ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual
- Part No:TT4GB-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 ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual (TT4GB-E-00)
File Details:
Hitachi ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual (TT4GB-E-00)
- Manual Language:English
- Pages: 597
- Size: 11.5 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW220 ZW250 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TT4GB-E-00) – PDF DOWNLOAD:
Image Preview:
Description:
Hitachi ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual (TT4GB-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 ZW220 ZW250 Wheel Loader Troubleshooting Technical Manual (TT4GB-E-00)
ZW220/250_TT4GB-E-00...................................................................................................... 1 INTRODUCTION.............................................................................................................. 2 SAFETY.................................................................................................................... 4 RECOGNIZE SAFETY INFORMATION.......................................................................................... 4 UNDERSTAND SIGNAL WORDS............................................................................................... 4 FOLLOW SAFETY INSTRUCTIONS............................................................................................ 5 PREPARE FOR EMERGENCIES............................................................................................... 5 WEAR PROTECTIVE CLOTHING.............................................................................................. 6 PROTECT AGAINST NOISE................................................................................................. 6 NSPECT MACHINE........................................................................................................ 6 GENERAL PRECAUTIONS FOR CAB........................................................................................... 7 USE HANDHOLDS AND STEPS............................................................................................... 8 ADJUST THE OPERATOR'S SEAT............................................................................................ 8 ENSURE SAFETY BEFORE RISING FROMOR LEAVING OPERATOR’S SEAT............................................................ 8 FASTEN YOUR SEAT BELT................................................................................................. 9 MOVE AND OPERATE MACHINE SAFELY....................................................................................... 9 HANDLE STARTING AIDS SAFELY........................................................................................... 9 OPERATE ONLY FROM OPERATOR'SSEAT...................................................................................... 10 JUMP STARTING......................................................................................................... 10 INVESTIGATE JOB SITE BEFOREHAND....................................................................................... 11 EQUIPMENT OF HEAD GUARD, ROPS,FOPS.................................................................................... 12 PROVIDE SIGNALS FOR JOBS INVOLVINGMULTIPLE NUMBERS OF MACHINES........................................................ 12 KEEP RIDERS OFF MACHINE............................................................................................... 13 DRIVE SAFELY.......................................................................................................... 13 DRIVE MACHINE SAFELY (WORK SITE)...................................................................................... 13 DRIVE SAFELY WITH BUCKET LOADED....................................................................................... 14 DRIVE ON SNOW SAFELY.................................................................................................. 14 TRAVEL ON PUBLIC ROADS SAFELY......................................................................................... 14 AVOID INJURY FROM ROLLAWAY ACCIDENTS.................................................................................. 15 AVOID ACCIDENTS FROM BACKING UPAND TURNING............................................................................ 16 AVOID POSITIONING BUCKET OVERANYONE................................................................................... 17 AVOID TIPPING......................................................................................................... 17 NEVER UNDERCUT A HIGH BANK............................................................................................ 18 DIG WITH CAUTION...................................................................................................... 18 PERFORM TRUCK LOADING SAFELY.......................................................................................... 18 AVOID POWER LINES..................................................................................................... 19 PRECAUTIONS FOR OPERATION............................................................................................. 19 PRECAUTIONS FOR LIGHTENING............................................................................................ 19 OBJECT HANDLING....................................................................................................... 19 PROTECT AGAINST FLYING DEBRIS......................................................................................... 20 PARK MACHINE SAFELY................................................................................................... 20 STORE ATTACHMENTS SAFELY.............................................................................................. 21 TRANSPORT SAFELY...................................................................................................... 21 HANDLE FLUIDS SAFELY-AVOID FIRES...................................................................................... 22 PRACTICE SAFE MAINTENANCE............................................................................................. 23 WARN OTHERS OF SERVICE WORK........................................................................................... 24 SUPPORT MACHINE PROPERLY.............................................................................................. 24 STAY CLEAR OF MOVING PARTS............................................................................................ 24 SUPPORT MAINTENANCE PROPERLY.......................................................................................... 25 PREVENT PARTS FROM FLYING............................................................................................. 25 PREVENT BURNS......................................................................................................... 26 REPLACE RUBBER HOSES PERIODICALLY..................................................................................... 26 PREVENT FIRES......................................................................................................... 28 EVACUATING IN CASE OF FIRE............................................................................................ 29 BEWARE OF EXHAUST FUMES............................................................................................... 29 PRECAUTIONS FOR WELDING ANDGRINDING................................................................................... 29 AVOID HEATING NEAR PRESSURIZEDFLUID LINES............................................................................. 30 AVOID APPLYING HEAT TO LINES CONTAININGFLAMMABLE FLUIDS............................................................... 30 REMOVE PAINT BEFORE WELDING ORHEATING................................................................................. 30 BEWARE OF ASBESTOS DUST............................................................................................... 31 PREVENT BATTERY EXPLOSIONS............................................................................................ 31 SERVICE AIR CONDITIONING SYSTEMSAFELY................................................................................. 31 HANDLE CHEMICAL PRODUCTS SAFELY....................................................................................... 32 DISPOSE OF WASTE PROPERLY............................................................................................. 32 BEFORE RETURNING THE MACHINE TOTHE CUSTOMER........................................................................... 33 SECTION AND GROUPCONTENTS................................................................................................. 34 SECTION 4 OPERATIONALPERFORMANCE TEST..................................................................................... 36 Group 1 Introduction.................................................................................................. 38 Operational Performance Tests..................................................................................... 38 Preparation for Performance Tests................................................................................. 39 Group 2 Standard...................................................................................................... 40 Operational PerformanceStandard Table ............................................................................ 40 Main Pump P-Q Curve............................................................................................... 50 Sensor Activating Range........................................................................................... 52 Group 3 Engine Test................................................................................................... 54 Engine Speed...................................................................................................... 54 Engine Compression Pressure....................................................................................... 56 Valve Clearance Adjustment........................................................................................ 57 Lubricant Consumption............................................................................................. 60 Group 4 Wheel Loader Test............................................................................................. 62 Travel Speed...................................................................................................... 62 Service Brake Function Check...................................................................................... 63 Service Brake Wear Amount......................................................................................... 64 Parking Brake Function Check...................................................................................... 65 Bucket and Bell Crank StopperClearances .......................................................................... 67 Hydraulic Cylinder Cycle Time..................................................................................... 69 Cylinder Drift Check.............................................................................................. 71 Bucket Levelness.................................................................................................. 72 Control Lever Operating Force..................................................................................... 73 Control Lever Stroke.............................................................................................. 74 Group 5 Component Test................................................................................................ 76 Primary Pilot Pressure............................................................................................ 76 Secondary Pilot Pressure.......................................................................................... 78 Solenoid Valve Set Pressure....................................................................................... 79 Main Pump Delivery Pressure....................................................................................... 81 Main Relief Valve Set Pressure.................................................................................... 83 Steering Relief Pressure.......................................................................................... 87 Overload Relief Valve Set Pressure................................................................................ 89 Main Pump Flow Rate............................................................................................... 91 Regulator Adjustment.............................................................................................. 95 Service Brake Pressure (Front and Rear)........................................................................... 97 Parking Brake Pressure............................................................................................ 99 Brake Accumulated Pressure........................................................................................101 Brake Warning Set Pressure (Decrease).............................................................................103 Brake Warning Set Pressure (Increase).............................................................................105 Transmission Clutch Pressure......................................................................................107 Torque Converter Pressure(Inlet and Outlet).......................................................................109 Group 6 Adjustment....................................................................................................112 Transmission Learning.............................................................................................112 Lift Arm Angle SensorLearning (Optional)..........................................................................117 Drive Belt Tension Adjustment.....................................................................................119 SECTION 5 TROUBLESHOOTING.................................................................................................122 Group 1 Diagnosing Procedure..........................................................................................126 Introduction......................................................................................................126 Diagnosing Procedure..............................................................................................127 How to Operate Service Made ofMonitor ............................................................................131 Display List of Monitor Service Mode..............................................................................132 Group 2 Dr.ZX.........................................................................................................134 Outline...........................................................................................................134 Operation.........................................................................................................135 Self-Diagnosing Result............................................................................................137 Select Controller.................................................................................................139 Main Controller...................................................................................................140 Main Menu Monitor Display (MainController) .......................................................................141 Setting (Main Controller).........................................................................................145 Record Data Display (Main Controller).............................................................................152 Password Change (Main Controller).................................................................................153 Engine Controller.................................................................................................154 Monitor Display (Engine Controller)...............................................................................155 Recorded Data Display (EngineController) .........................................................................159 Password Change (Engine Controller)ICF Controller ................................................................160 ICF Various Setup (ICF Controller)................................................................................162 Save Data Check (ICF Controller)..................................................................................173 Password Change (ICF Controller)..................................................................................174 Monitor Unit......................................................................................................176 Monitoring (Monitor Unit).........................................................................................177 Various Settings (Monitor Unit)...................................................................................179 Internal Hour Meter Synchronization...............................................................................180 Password Change (Monitor Unit)....................................................................................181 TCU Controller....................................................................................................182 Monitor Display (TCU Controller)..................................................................................183 Recorded Data Display (TCU Controller)............................................................................187 Password Change (TCU Controller)..................................................................................188 Group 3 e-Wheel.......................................................................................................190 Outline...........................................................................................................190 List of Daily Report Data.........................................................................................191 List of Frequency Distribution Data...............................................................................192 List of Total Operationg Hours....................................................................................193 List of Alarm.....................................................................................................194 List of failure ..................................................................................................195 How to Download and Upload Data ofICF.............................................................................196 Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX ...........................................199 List of ICF Fault Code ...........................................................................................211 List of Fault Code of SattelliteCommunication Terminal............................................................212 Group 4 Component Layout..............................................................................................216 Main Component Layout (Overview)..................................................................................216 Main Component Layout (Upper- structure) ........................................................................217 Main Component Layout (TravelSystem) .............................................................................218 Electric Component Layout (Overview)..............................................................................219 Electrical System (Cab)...........................................................................................220 Engine and Fan Pump...............................................................................................225 Pump Device, Drive Unit...........................................................................................226 Control Valve.....................................................................................................227 Ride Control Valve ,Charging Block,Fan Motor, Parking Brake SolenoidValve.........................................228 Steering Valve, EmergencySteering Pump............................................................................229 Components in Control Valve.......................................................................................231 Components in Steering Valve......................................................................................243 Components in Charging Block......................................................................................247 Components in Ride Control Valve..................................................................................253 Side View of Transmission.........................................................................................257 Front View of Transmission........................................................................................258 Pressure Sensor Ports ofTransmission .............................................................................259 Cross-Sectional Drawing ofTransmission ...........................................................................260 Cross-Sectional Drawing of TorqueConverter .......................................................................261 Cross-Sectional Drawing ofTransmission Control Valve .............................................................262 Circuit of Drive Unit ............................................................................................263 Group 5 Troubleshooting A.............................................................................................264 Troubleshooting A Procedure.......................................................................................264 MC Fault Code List................................................................................................265 ECM Fault Code List...............................................................................................279 TCU Fault Code List...............................................................................................303 ICF Fault Code List...............................................................................................321 Satellite Terminal Fault Code List................................................................................323 Monitor Unit Fault Code List......................................................................................325 Controller Hardware FailureMC Fault Codes 11000 to 11002..........................................................326 MC Fault Code 11003...............................................................................................327 MC Fault Code 11004...............................................................................................328 CAN Harness Check.................................................................................................329 Engine FailureMC Fault Code 11103.................................................................................354 Pump FailureMC Fault Code 11204...................................................................................355 MC Fault Code 11209...............................................................................................356 Pilot FailureMC Fault Code 11313..................................................................................357 Proportional Solenoid Valve FailureMC Fault Code 11412............................................................358 MC Fault Code 11413...............................................................................................359 CAN Data Reception FailureMC Fault Codes 11910, 11920.............................................................360 CAN Harness Check(MC Fault Codes 11910, 11920)....................................................................361 MC Fault Code 11914...............................................................................................364 CAN Harness Check(MC Fault Code 11914)............................................................................365 MC Fault Codes 11912, 11913,11916, 11917 .........................................................................368 CAN Harness Check(MC Fault Codes 11912, 11913,11916, 11917).......................................................369 Other FailuresMC Fault Code 11901.................................................................................372 Proportional Solenoid Valve TrubleCheck ..........................................................................373 ECM, Sensor SystemECM Fault Codes 100, 102, 105, 108,110, 157, 172 ...............................................376 ECM Fault Codes 174, 636, 723,10001...............................................................................377 ECM, External Device SystemECM Fault Codes 651, 652, 653, 654,655, 656, 1347, 10002 ..............................378 ECM, Fuel SystemECM Fault Codes 157, 633, 1239,1240...............................................................379 ECM, Engine ProtectionECM Fault Codes 110, 190 ...................................................................380 ECM, External Circuit SystemECM Fault Codes 987, 1485.............................................................381 ECM, Internal Circuit SystemECM Fault Codes 628, 1077, 1079,1080, 10003, 10004, 10005 ............................382 ECM Fault Codes 10006, 10007,10008, 10009, 10010, 10011, 10013....................................................383 ECM, Communication SystemECM Fault Codes 639......................................................................384 Role and Connection of EachTerminal in TCU .......................................................................385 ICF, Satellite Terminal Fault Codes14000 to 14003 ................................................................388 ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106...................................................392 Monitor Unit Fault Codes 13306,13308 .............................................................................394 Monitor Unit Fault Code 13312.....................................................................................395 Monitor Unit Fault Code 13314.....................................................................................396 Group 6 Troubleshooting B.............................................................................................398 Troubleshooting B Procedure.......................................................................................398 Relationship between Machine TroubleSymptoms and Related Parts ...................................................399 Correlation between TroubleSymptoms and Part Failures ............................................................415 Engine System Troubleshooting.....................................................................................429 Front Attachment SystemTroubleshooting ...........................................................................438 Travel System Troubleshooting.....................................................................................457 Brake System Troubleshooting......................................................................................473 Steering System Troubleshooting...................................................................................481 Other System Troubleshooting......................................................................................484 Exchange Inspection...............................................................................................506 Bleeding Air from Brake (Axle)....................................................................................508 One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ....509 Group 7 Troubleshooting C.............................................................................................524 Troubleshooting C (Trouble Shootingfor Monitor) Procedure.........................................................524 Malfunction of Indicator Light CheckSystem .......................................................................525 Malfunction of Buzzer in Monitor..................................................................................527 Malfunction of Coolant TemperatureGauge ..........................................................................529 Malfunction of Transmission OilTemperature Gauge..................................................................531 Malfunction of Fuel Gauge.........................................................................................533 Malfunction of Turn Signal Indicators(Left and Right).............................................................535 Malfunction of Hazard Light Indicator.............................................................................536 Malfunction of High Beam Indicator................................................................................537 Malfunction of Working Light Indicator............................................................................539 Malfunction of Forward/ReverseSwitch Indicator ...................................................................541 Malfunction of Maintenance Indicator..............................................................................543 Malfunction of Preheat Indicator..................................................................................544 Malfunction of Transmission OilTemperature........................................................................545 Malfunction of Hydraulic OilTemperature Indicator ................................................................547 Malfunction of Transmission WarningIndicator......................................................................549 Malfunction of Air Filter RestrictionIndicator....................................................................551 Malfunction of Engine Oil PressureIndicator.......................................................................553 Malfunction of Overheat Indicator.................................................................................555 Malfunction of Engine WarningIndicator............................................................................557 Malfunction of Stop Indicator.....................................................................................558 Malfunction of Service Indicator..................................................................................559 Malfunction of Parking Brake Indicator............................................................................561 Malfunction of Clearance LightIndicator...........................................................................563 Malfunction of Brake Low Oil PressureIndicator....................................................................564 Malfunction of Brake Low Oil LevelIndicator.......................................................................565 Malfunction of Emergency SteeringIndicator (Optional) ............................................................567 Malfunction of Low Steering OilPressure Indicator (Optional) .....................................................569 Malfunction of Discharge WarningIndicator.........................................................................571 Malfunction of Monitor Display....................................................................................573 Malfunction of Ride Control Indicator.............................................................................574 Malfunction of Engine CoolantTemperature Display .................................................................575 Group 8 Electrical System Inspection..................................................................................576 Precautions for Inspection andMaintenance ........................................................................576 Instructions for DisconnectingConnectors .........................................................................578 Fuse Inspection...................................................................................................581 Fusible Link Inspection...........................................................................................583 Battery Voltage Check.............................................................................................584 Alternator Check..................................................................................................585 Continuity Check..................................................................................................587 Voltage and Current Measurement...................................................................................589 Check by False Signal.............................................................................................592 SERVICE MANUAL REVISION REQUEST FORM......................................................................................596 THE ATTACHED DIAGRAM LIST.................................................................................................597
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
