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Hitachi ZW250-5B Wheel Loader Troubleshooting Technical Manual (TTNEC-EN-00) – PDF Download
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- Hitachi ZW250-5B Wheel Loader Troubleshooting Technical Manual
- Part No:TTNEC-EN-00
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Description
Hitachi ZW250-5B Wheel Loader Troubleshooting Technical Manual (TTNEC-EN-00)
File Details:
Hitachi ZW250-5B Wheel Loader Troubleshooting Technical Manual (TTNEC-EN-00)
- Manual Language:English
- Pages: 514
- Size:5.93 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW250-5B WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTNEC-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW250-5B Wheel Loader Troubleshooting Technical Manual (TTNEC-EN-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 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 ZW250-5B Wheel Loader Troubleshooting Technical Manual (TTNEC-EN-00)
TTNEC-EN-00..................................................................................... 1 INTRODUCTION................................................................................ 3 To The Reader........................................................................... 3 Additional References................................................................... 3 Manual Composition...................................................................... 3 Page Number............................................................................. 3 Safety Alert Symbol and Headline Notations.............................................. 4 Units Used.............................................................................. 4 Symbol and Abbreviation..................................................................... 5 Symbol and Abbreviation................................................................. 5 SAFETY...................................................................................... 7 Recognize Safety Information............................................................ 7 Understand Signal Words................................................................. 7 Follow Safety Instructions.............................................................. 8 Prepare for Emergencies................................................................. 9 Wear Protective Clothing................................................................ 9 Protect Against Noise................................................................... 10 Inspect Machine......................................................................... 10 General Precautions for Cab............................................................. 11 Use Handrails and Steps................................................................. 12 Never Ride Attachment................................................................... 12 Adjust Operator’s Seat.................................................................. 12 Ensure Safety Before Rising from or Leaving Operator’s Seat............................. 13 Fasten Your Seat Belt................................................................... 13 Move and Operate Machine Safely......................................................... 14 Handle Starting Aids Safely............................................................. 14 Operate Only from Operator’s Seat....................................................... 15 Jump Starting........................................................................... 15 Investigate Job Site Beforehand......................................................... 16 Equipment of Head Guard, ROPS, FOPS..................................................... 17 Provide Signals for Jobs Involving Multiple Machines.................................... 17 Keep Riders Off Machine................................................................. 18 Drive Safely............................................................................ 18 Drive Machine Safely (Work Site)........................................................ 19 Drive Safely with Bucket Loaded......................................................... 20 Drive on Snow Safely.................................................................... 20 Travel on Public Roads Safely........................................................... 21 Avoid Injury from Rollaway Accidents.................................................... 21 Avoid Accidents from Backing Up and Turning............................................. 22 Avoid Positioning Bucket or Attachment Over Anyone...................................... 23 Avoid Tipping........................................................................... 23 Never Undercut a High Bank.............................................................. 24 Dig with Caution........................................................................ 24 Perform Truck Loading Safely............................................................ 24 Avoid Power Lines....................................................................... 25 Precautions for Operation............................................................... 25 Precautions for Lightning............................................................... 25 Object Handling......................................................................... 26 Protect Against Flying Debris........................................................... 26 Park Machine Safely..................................................................... 27 Store Attachments Safely................................................................ 27 Transport Safely........................................................................ 28 Handle Fluids Safely−Avoid Fires........................................................ 29 Practice Safe Maintenance............................................................... 30 Warn Others of Service Work............................................................. 31 Support Machine Properly................................................................ 31 Stay Clear of Moving Parts.............................................................. 32 Support Maintenance Properly............................................................ 32 Prevent Parts from Flying............................................................... 33 Prevent Burns........................................................................... 33 Replace Rubber Hoses Periodically....................................................... 34 Avoid High-Pressure Fluids.............................................................. 34 Prevent Fires........................................................................... 35 Evacuating in Case of Fire.............................................................. 37 Beware of Exhaust Fumes................................................................. 37 Precautions for Welding and Grinding.................................................... 37 Avoid Heating Near Pressurized Fluid Lines.............................................. 38 Avoid Applying Heat to Lines Containing Flammable Fluids................................ 38 Precautions for Handling Accumulator and Gas Damper..................................... 38 Remove Paint Before Welding or Heating.................................................. 39 Beware of Asbestos and Silicon Dust and Other Contamination............................. 39 Prevent Battery Explosions.............................................................. 40 Service Air Conditioning System Safely.................................................. 40 Handle Chemical Products Safely......................................................... 41 Dispose of Waste Properly............................................................... 41 Notes for Muffler Filter................................................................ 42 Precautions for Communication Terminal.................................................. 42 Precaution for Communication Terminal Equipment......................................... 43 Before Returning the Machine to the Customer............................................ 45 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 Main Pump P-Q Diagram............................................................... 62 Sensor Activating Range............................................................. 64 Group 3 Engine Test..................................................................... 65 Engine Speed........................................................................ 65 Lubricant Consumption............................................................... 67 Group 4 Machine Performance Test........................................................ 69 Travel Speed........................................................................ 69 Service Brake Function Check........................................................ 72 Service Brake Wear Amount........................................................... 74 Parking Brake Function Check........................................................ 75 Bucket Stopper and Bell Crank Stopper Clearance..................................... 76 Hydraulic Cylinder Cycle Time....................................................... 78 Dig Function Drift Check............................................................ 80 Bucket Levelness.................................................................... 81 Control Lever Operating Force....................................................... 82 Control Lever Stroke................................................................ 84 Group 5 Component Test.................................................................. 85 Primary Pilot Pressure (Including Brake Circuit).................................... 85 Secondary Pilot Pressure............................................................ 88 Solenoid Valve Set Pressure......................................................... 90 Main Pump Delivery Pressure......................................................... 92 Main Relief Set Pressure............................................................ 94 Steering Relief Pressure............................................................ 98 Overload Relief Valve Set Pressure..................................................100 Main Pump Flow Rate Measurement.....................................................102 Service Brake Pressure (Front and Rear).............................................110 Parking Brake Pressure..............................................................112 Brake Accumulator Pressure..........................................................114 Brake Warning Pressure (Pressure-Decreasing)........................................116 Brake Warning Pressure (Pressure-Increasing)........................................118 Transmission Clutch Pressure........................................................120 Torque Converter Pressure (Inlet)...................................................122 Group 6 Adjustment......................................................................125 Measuring Method of No-Load-Max Differential Pressure...............................125 Zero-Point Calibration (Correction).................................................127 SECTION 5 TROUBLESHOOTING...................................................................131 Group 1 Diagnosing Procedure............................................................133 Introduction........................................................................133 Diagnosis Procedure.................................................................134 Electric System Inspection..........................................................137 Precautions for Inspection and Maintenance..........................................138 Instructions for Disconnecting Connectors...........................................140 Fuse Inspection.....................................................................142 Fusible Link Inspection.............................................................144 Battery Voltage Check...............................................................145 Alternator Check....................................................................146 Continuity Check....................................................................147 Voltage and Current Measurement.....................................................148 Check by False Signal...............................................................155 Test Harness........................................................................156 Group 2 Monitor.........................................................................159 Outline.............................................................................159 Operating Procedures of Service Menu................................................160 Engine Tachometer...................................................................195 Transmission Oil Temperature Gauge and Brake Oil Pressure Gauge.....................196 Coolant Temperature Gauge...........................................................197 Group 3 e-Service.......................................................................199 Outline.............................................................................199 List of Operation Data..............................................................200 Snapshot Data.......................................................................204 Communication System................................................................205 Group 4 Component Layout................................................................207 Main Component (Overview)...........................................................207 Main Component......................................................................208 Main Component......................................................................209 Electric Component Layout (Overview)................................................210 Electrical System (Cab).............................................................211 Engine and Fan Pump.................................................................219 Pump Device.........................................................................221 Control Valve.......................................................................222 Manifold Valve......................................................................223 Brake Charge Valve..................................................................223 Parking Brake Solenoid Valve........................................................223 3-Spool Solenoid Valve Unit.........................................................223 Steering Valve......................................................................224 Flow Regulator Valve................................................................224 Emergency Steering Pump.............................................................224 Components in Control Valve.........................................................226 Components in Steering Valve........................................................232 Components in Brake Charge Valve....................................................234 Components in Manifold Valve........................................................236 Section of Flow Regulator Valve.....................................................238 Components in Fan Valve.............................................................239 Side View of Transmission...........................................................242 Transmission Pressure Sensor Port...................................................243 Front View of Transmission..........................................................244 Section of Transmission (Section A-A)...............................................245 Section of Torque Converter.........................................................246 Section of Transmission Control Valve...............................................247 Drive Unit Circuit..................................................................248 Group 5 Troubleshooting A...............................................................249 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...........249 MC Fault Code List..................................................................251 Monitor Controller (Monitor) Fault Code List........................................265 Monitor Controller (Information) Fault Code List....................................267 Column Display Controller Fault Code List...........................................269 Air Conditioner Controller Fault Code List..........................................271 Air Conditioner Controller Fault Code List..........................................272 Communication Terminal Fault Code List..............................................273 ECM Fault Code List.................................................................274 TCU Fault Code List.................................................................298 MC Fault Codes 111000 to 111002.....................................................319 MC Fault Code 111003................................................................320 MC Fault Codes 111006, 111007, 111009, 111011.......................................323 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113012.............323 CAN1 Harness Check..................................................................324 CAN3 (Engine) Harness Check.........................................................328 MC Fault Codes 111005, 111008, 111010, 111014, 111025...............................331 Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007.....................331 Column Display Controller Fault Code 115002.........................................331 CAN2 Harness Check..................................................................332 MC Fault Code 111100................................................................335 MC Fault Code 111103................................................................336 MC Fault Codes 111205, 111207.......................................................337 MC Fault Codes 111200, 111202, 111203...............................................338 MC Fault Codes 111217, 111312.......................................................339 MC Fault Codes 111204, 111206.......................................................340 MC Fault Code 111208................................................................341 MC Fault Codes 111311, 111313.......................................................342 MC Fault Code 111406................................................................343 MC Fault Code 111410................................................................344 MC Fault Code 111411................................................................345 MC Fault Code 111412................................................................346 MC Fault Code 111413................................................................347 MC Fault Code 111422................................................................348 MC Fault Code 111901................................................................349 MC Fault Code 111902................................................................350 MC Fault Codes 120000, 120002 to 120005.............................................351 MC Fault Codes 120008, 120014.......................................................352 MC Fault Codes 120101 to 120106.....................................................353 Column Display Controller Fault Code 115001.........................................354 Column Display Controller Fault Code 115011.........................................355 Monitor Controller (Monitor) Fault Code 120300......................................356 Monitor Controller (Information) Fault Codes 120400, 120401.........................357 Column Display Controller (Information) Fault Codes 120500 to 120505................358 Air Conditioner Controller Fault Codes 11 to 22.....................................359 Air Conditioner Controller Fault Codes 43 to 92.....................................360 Group 6 Troubleshooting B...............................................................361 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....361 Relationship between Machine Trouble Symptoms and Related Parts.....................363 Correlation between Trouble Symptoms and Part Failures..............................386 Engine System Troubleshooting.......................................................409 All Actuator System Troubleshooting.................................................415 Front Attachment System Troubleshooting.............................................421 Steering System Troubleshooting.....................................................431 Travel System Troubleshooting.......................................................435 Brake System Troubleshooting........................................................445 Other System Troubleshooting........................................................449 Exchange Inspection.................................................................463 Air Bleeding Procedures for Brake (Axle)............................................465 Group 7 Air Conditioner.................................................................467 Outline.............................................................................467 Functions of Main Parts.............................................................470 Troubleshooting.....................................................................475 Air Conditioner Controller Fault Code List..........................................476 Air Conditioner Controller Fault Codes 11 to 22.....................................477 Air Conditioner Controller Fault Codes 43 to 92.....................................478 Work after Replacing Components.....................................................500 Refill Compressor Oil...............................................................501 Charge Air Conditioner with Refrigerant.............................................502 Hose and Pipe Tightening Torque.....................................................510 SERVICE MANUAL REVISION REQUEST FORM........................................................513 The Attached Diagram List...................................................................514
Please Note:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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Alistair Remington –
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