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Hitachi ZW250-6 Wheel Loader Troubleshooting Technical Manual (TTNEM50-EN-00) – PDF Download
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- Hitachi ZW250-6 Wheel Loader Troubleshooting Technical Manual
- Part No:TTNEM50-EN-00
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Description
Hitachi ZW250-6 Wheel Loader Troubleshooting Technical Manual (TTNEM50-EN-00)
File Details:
Hitachi ZW250-6 Wheel Loader Troubleshooting Technical Manual (TTNEM50-EN-00)
- Manual Language:English
- Pages: 496
- Size: 12.6 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW250-6 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTNEM50-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW250-6 Wheel Loader Troubleshooting Technical Manual (TTNEM50-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 ZW250-6 Wheel Loader Troubleshooting Technical Manual (TTNEM50-EN-00)
TTNEM50-EN-00............................................................................ 1 CONTENTS............................................................................. 3 INTRODUCTION......................................................................... 7 To The Reader.................................................................... 7 Additional References............................................................ 7 Manual Composition............................................................... 7 Page Number...................................................................... 7 Trademark........................................................................ 7 Safety Alert Symbol and Headline Notations....................................... 8 Units Used....................................................................... 8 SYMBOL AND ABBREVIATION.............................................................. 9 SAFETY............................................................................... 11 Recognize Safety Information..................................................... 11 Understand Signal Words.......................................................... 11 Follow Safety Instructions....................................................... 12 Prepare for Emergencies.......................................................... 13 Wear Protective Clothing......................................................... 13 Protect Against Noise............................................................ 14 Inspect Machine.................................................................. 14 General Precautions for the Cab.................................................. 15 Use Handrails and Steps.......................................................... 16 Never Ride Attachment............................................................ 16 Adjust Operator’s Seat........................................................... 16 Ensure Safety Before Rising from or Leaving Operator’s Seat...................... 17 Fasten Your Seat Belt............................................................ 17 Move and Operate Machine Safely.................................................. 18 Handle Starting Aids Safely...................................................... 18 Operate Only from Operator’s Seat................................................ 19 Jump Starting.................................................................... 19 Investigate Job Site Beforehand.................................................. 20 Equipment of Head Guard, ROPS, FOPS.............................................. 21 Provide Signals for Jobs Involving Multiple Machines............................. 21 Keep Riders Off Machine.......................................................... 22 Drive Safely..................................................................... 22 Drive Machine Safely (Work Site)................................................. 23 Drive Safely with Bucket Loaded.................................................. 24 Drive on Snow Safely............................................................. 24 Travel on Public Roads Safely.................................................... 25 Avoid Injury from Rollaway Accidents............................................. 25 Avoid Accidents from Backing Up and Turning...................................... 26 Avoid Positioning Bucket or Attachment Over Anyone............................... 27 Avoid Tipping.................................................................... 27 Never Undercut a High Bank....................................................... 28 Dig with Caution................................................................. 28 Perform Truck Loading Safely..................................................... 28 Avoid Power Lines................................................................ 29 Precautions for Operation........................................................ 29 Precautions for Lightning........................................................ 29 Object Handling.................................................................. 30 Protect Against Flying Debris.................................................... 30 Park Machine Safely.............................................................. 31 Store Attachments Safely......................................................... 31 Transport Safely................................................................. 32 Handle Fluids Safely−Avoid Fires................................................. 33 Practice Safe Maintenance........................................................ 34 Warn Others of Service Work...................................................... 35 Support Machine Properly......................................................... 35 Stay Clear of Moving Parts....................................................... 36 Support Maintenance Properly..................................................... 36 Prevent Parts from Flying........................................................ 37 Prevent Burns.................................................................... 37 Replace Rubber Hoses Periodically................................................ 38 Avoid High-Pressure Fluids....................................................... 38 Prevent Fires.................................................................... 39 Evacuating in Case of Fire....................................................... 41 Beware of Exhaust Fumes.......................................................... 41 Precautions for Welding and Grinding............................................. 41 Avoid Heating Near Pressurized Fluid Lines....................................... 42 Avoid Applying Heat to Lines Containing Flammable Fluids......................... 42 Precautions for Handling Accumulator and Gas Damper.............................. 42 Remove Paint Before Welding or Heating........................................... 43 Beware of Asbestos and Silica Dust and Other Contamination....................... 43 Prevent Battery Explosions....................................................... 44 Service Air Conditioning System Safely........................................... 44 Handle Chemical Products Safely.................................................. 45 Dispose of Waste Properly........................................................ 45 Notes on Aftertreatment Device................................................... 46 Precautions for Communication Terminal........................................... 46 Precaution for Communication Terminal Equipment.................................. 47 Before Returning the Machine to the Customer..................................... 48 SECTION AND GROUP CONTENTS........................................................... 49 SECTION 4 OPERATIONAL PERFORMANCE TEST............................................... 51 Group 1 Introduction............................................................. 53 Operational Performance Tests................................................ 53 Preparation for Performance Tests............................................ 54 Group 2 Standard................................................................. 55 Operational Performance Standard Table....................................... 55 Main Pump P-Q Diagram........................................................ 64 Sensor Activating Range...................................................... 66 Group 3 Engine Test.............................................................. 67 Engine Speed................................................................. 67 Lubricant Consumption........................................................ 69 Group 4 Machine Performance Test................................................. 71 Travel Speed................................................................. 71 Service Brake Function Check................................................. 74 Service Brake Wear Amount.................................................... 76 Parking Brake Function Check................................................. 77 Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance............... 78 Hydraulic Cylinder Cycle Time................................................ 80 Cylinder Drift Check......................................................... 82 Bucket Levelness............................................................. 83 Control Lever Operating Force................................................ 84 Control Lever Stroke......................................................... 86 Group 5 Component Test........................................................... 87 Primary Pilot Pressure (Including Brake Circuit)............................. 87 Secondary Pilot Pressure..................................................... 90 Solenoid Valve Set Pressure.................................................. 92 Main Pump Delivery Pressure.................................................. 94 Loading Circuit Main Relief Set Pressure..................................... 96 Steering Circuit Relief Set Pressure.........................................100 Loading Overload Relief Valve Set Pressure...................................102 Main Pump Flow Rate Measurement..............................................104 Service Brake Pressure (Front and Rear)......................................112 Parking Brake Release Pressure...............................................114 Brake Accumulator Pressure...................................................116 Brake Warning Pressure (Pressure-Decreasing).................................118 Brake Warning Pressure (Pressure-Increasing).................................120 Transmission Clutch Pressure.................................................122 Torque Converter Pressure....................................................124 Group 6 Adjustment...............................................................127 Rewrite of Aftertreatment Device Serial No...................................127 Clean DEF Tank...............................................................128 Transmission Learning........................................................129 Lift Arm Angle Sensor Learning...............................................129 Digging Position Adjustment..................................................129 SECTION 5 TROUBLESHOOTING............................................................133 Group 1 Diagnosing Procedure.....................................................135 Introduction.................................................................135 Diagnosis Procedure..........................................................136 Electric System Inspection...................................................139 Precautions for Inspection and Maintenance...................................140 Instructions for Disconnecting Connectors....................................142 Fuse Inspection..............................................................144 Fusible Link Inspection......................................................146 Battery Voltage Check........................................................147 Alternator Check.............................................................148 Continuity Check.............................................................150 Voltage and Current Measurement..............................................152 Check by False Signal........................................................159 Test Harness.................................................................160 Surge Voltage and Surge Suppression Diodes...................................162 Group 2 Monitor..................................................................163 Outline......................................................................163 Operating Procedures of Service Menu.........................................164 Troubleshooting..............................................................166 Monitoring...................................................................168 Controller Version...........................................................178 Issued Warning Record........................................................179 Communication Terminal Status................................................184 Machine Setting..............................................................186 Aftertreatment Device No.....................................................195 Engine Tachometer............................................................196 Transmission Oil Temperature Gauge and DEF/AdBlue Level Gauge................197 Coolant Temperature Gauge....................................................198 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 Electrical System (Overview).................................................210 Air Cleaner and Radiator Assembly............................................211 Battery Box..................................................................213 Hydraulic Oil Tank...........................................................214 Fuel Tank....................................................................215 Drive Unit...................................................................216 Front Axle...................................................................217 Cab..........................................................................218 Engine.......................................................................224 Aftertreatment Device........................................................225 Fan Valve....................................................................226 Pump Device..................................................................227 Multiple Control Valve.......................................................227 Manifold Valve...............................................................228 Parking Brake Solenoid Valve.................................................228 Brake Charge Valve...........................................................228 2-Spool Solenoid Valve Unit..................................................228 Steering Valve...............................................................229 Emergency Steering Pump......................................................229 Flow Regulator Valve.........................................................229 DEF Tank.....................................................................230 DEF Supply Module............................................................230 Group 5 Troubleshooting A........................................................231 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....231 MPDr. Fault Code Reference Table.............................................233 MC Fault Code List...........................................................239 Monitor Controller (Monitor) Fault Code List.................................251 Monitor Controller (Information) Fault Code List.............................252 Column Display Controller Fault Code List....................................255 Air Conditioner Controller Fault Code List...................................257 Communication Terminal Fault Code List.......................................258 ECM Fault Code List..........................................................259 TCU Fault Code List..........................................................289 MC Fault Codes 111000 to 111002..............................................309 MC Fault Code 111003.........................................................310 MC Fault Codes 111006, 111007, 111009, 111011................................313 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113012......313 CAN1 Harness Check...........................................................314 CAN3 Harness Check...........................................................318 MC Fault Codes 111008, 111010, 111014, 111025................................321 Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007..............321 CAN2 Harness Check...........................................................322 MC Fault Code 111100.........................................................325 MC Fault Codes 111103, 111106, 111107........................................326 MC Fault Codes 111205, 111207................................................327 MC Fault Codes 111200, 111202, 111203........................................328 MC Fault Codes 111217, 111312................................................329 MC Fault Code 111204.........................................................330 MC Fault Codes 111206, 111208................................................331 MC Fault Codes 111311, 111313................................................332 MC Fault Code 111410.........................................................333 MC Fault Code 111411.........................................................334 MC Fault Code 111412.........................................................335 MC Fault Code 111413.........................................................336 MC Fault Code 111422.........................................................337 MC Fault Code 111901.........................................................338 MC Fault Code 111902.........................................................339 MC Fault Codes 120000, 120002 to 120005......................................340 MC Fault Code 120014.........................................................341 Monitor Controller Fault Code 115001.........................................343 Monitor Controller (Information) Fault Code 113311...........................344 Monitor Controller (Monitor) Fault Code 120300...............................345 Monitor Controller (Information) Fault Codes 120400, 120401..................346 Column Display Controller Fault Codes 120500 to 120504.......................347 Column Display Controller (Information) Fault Codes 120505 to 120507.........348 Group 6 Troubleshooting B........................................................349 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.....349 Relationship between Machine Trouble Symptoms and Related Parts.............351 Correlation between Trouble Symptoms and Part Failures.......................374 Engine System Troubleshooting................................................394 All Actuator System Troubleshooting..........................................400 Front Attachment System Troubleshooting......................................405 Steering System Troubleshooting..............................................414 Travel System Troubleshooting................................................418 Brake System Troubleshooting.................................................427 Other System Troubleshooting.................................................431 Exchange Inspection..........................................................445 Air Bleeding Procedures for Brake (Axle).....................................447 Group 7 Air Conditioner..........................................................449 Outline......................................................................449 Functions of Main Parts......................................................452 Troubleshooting..............................................................457 Air Conditioner Controller Fault Code List...................................458 Air Conditioner Controller Fault Codes 11 to 22..............................459 Air Conditioner Controller Fault Codes 43 to 92..............................460 Work after Replacing Components..............................................482 Refill Compressor Oil........................................................483 Charge Air Conditioner with Refrigerant......................................484 Hose and Pipe Tightening Torque..............................................492 SERVICE MANUAL REVISION REQUEST FORM.................................................495 The Attached Diagram List............................................................496
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]
