Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW) – PDF Download

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Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)

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Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)

• Manual Language:English
• Pages: 533
• Size: 8.66 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW310 PERFORMANCE CHECK & TROUBLESHOOTING TRAINING TEXT MANUAL (TTLA-0669-ZW) – PDF DOWNLOAD:

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Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)

Use operational performance test procedure to quantitatively check all system and functions on the machine.
Purpose of Performance Tests
1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.
2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.
3. To economically operate the machine under optimal conditions.
Kinds of Tests
1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct, but also in what range the test data are.
2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.
The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.
Definition of “Performance Standard”
1. Operation speed values and dimensions of the new machine.
2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary

Table Of Contents:

Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)

MATERIALS TOP.............................................................................................................  0
PERFORMANCE TEST&TROUBLESHOOTING..........................................................................................  1
SECTION 4 OPERATIONALPERFORMANCE TEST.....................................................................................  2
	Group 1 Introduction..................................................................................................  4
		Operational Performance Tests.....................................................................................  4
		Preparation for Performance Tests.................................................................................  5
	Group 2 Standard......................................................................................................  6
		Operational Performance Standard Table............................................................................  6
		Main Pump P-Q Curve............................................................................................... 16
		Sensor Activating Range........................................................................................... 18
	Group 3 Engine Test................................................................................................... 20
		Engine Speed...................................................................................................... 20
		Engine Compression Pressure ...................................................................................... 23
		Valve Clearance................................................................................................... 25
		Lubricant Consumption ............................................................................................ 27
	Group 4 Wheel Loader Test............................................................................................. 28
		Travel Speed...................................................................................................... 28
		Service Brake Function Check...................................................................................... 29
		Service Brake Wear Amount ........................................................................................ 30
		Parking Brake Function Check...................................................................................... 31
		Bucket Stopper and Bell CrankClearances .......................................................................... 33
		Hydraulic Cylinder Cycle Time..................................................................................... 35
		Cylinder Drift Check.............................................................................................. 37
		Bucket Levelness.................................................................................................. 38
		Control Lever Operating Force..................................................................................... 39
		Control Lever Stroke.............................................................................................. 40
	Group 5 Component Test................................................................................................ 42
		Primary Pilot Pressure............................................................................................ 42
		Secondary Pilot Pressure.......................................................................................... 44
		Solenoid Valve Set Pressure....................................................................................... 45
		Main Pump Delivery Pressure....................................................................................... 47
		Main Relief Pressure.............................................................................................. 49
		Steering Relief Pressure.......................................................................................... 51
		Overload Relief Valve Set Pressure................................................................................ 53
		Main Pump Flow Rate............................................................................................... 55
		Regulator Adjustment.............................................................................................. 59
		Service Brake Pressure (Front and Rear)........................................................................... 61
		Parking Brake Pressure............................................................................................ 63
		Brake Accumulated Pressure........................................................................................ 65
		Brake Warning Set Pressure (Decrease)............................................................................. 67
		Brake Warning Set Pressure (Increase)............................................................................. 69
		Transmission Clutch Pressure...................................................................................... 71
		Torque Converter Pressure(Inlet and Outlet)....................................................................... 72
	Group 6 Adjustment.................................................................................................... 74
		Transmission Learning............................................................................................. 74
		Lift Arm Angle SensorLearning (Optional).......................................................................... 79
		Unit Injector Setting............................................................................................. 81
SECTION 5 TROUBLESHOOTING................................................................................................. 86
	Group 1 Diagnosing Procedure.......................................................................................... 92
		Introduction...................................................................................................... 92
		Diagnosing Procedure.............................................................................................. 93
		How to Operate Service Made ofMonitor............................................................................. 97
		Display List of Monitor Service Mode.............................................................................. 98
	Group 2 Dr.ZX.........................................................................................................100
		Outline...........................................................................................................100
		Operation.........................................................................................................101
		Self-Diagnosing Result............................................................................................103
		Select Controller.................................................................................................105
		Main Controller...................................................................................................106
		Main Menu Monitor Display (MainController) .......................................................................107
		Setting (Main Controller).........................................................................................111
		Record Data Display (Main Controller).............................................................................118
		Password Change (Main Controller).................................................................................119
		Engine Controller.................................................................................................120
		Monitor Display (Engine Controller)...............................................................................121
		Recorded Data Display (EngineController) .........................................................................125
		Password Change (Engine Controller)...............................................................................126
		ICF Controller ...................................................................................................128
		ICF Various Setup (ICF Controller)................................................................................129
		Save Data Check (ICF Controller)..................................................................................139
		Password Change (ICF Controller)..................................................................................140
		Monitor Unit .....................................................................................................142
		Monitoring (Monitor Unit).........................................................................................143
		Various Settings (Monitor Unit)...................................................................................145
		Internal Hour Meter Synchronization...............................................................................146
		Password Change (Monitor Unit)....................................................................................147
	Group 3 e-Wheel.......................................................................................................148
		Outline...........................................................................................................148
		List of Daily Report Data.........................................................................................149
		List of Frequency Distribution Data...............................................................................150
		List of Total Operationg Hours....................................................................................151
		List of Alarm.....................................................................................................152
		List of failure...................................................................................................153
		How to Download and Upload Data ofICF.............................................................................154
		Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX............................................157
		List of ICF Fault Code............................................................................................169
		List of Fault Code of SattelliteCommunication Terminal............................................................170
	Group 4 Component Layout..............................................................................................174
		Main Component Layout (Overview)..................................................................................174
		Main Component Layout (Upper-structure) ..........................................................................175
		Main Component Layout (TravelSystem)..............................................................................176
		Electric Component Layout (Overview)..............................................................................177
		Electrical System (Cab) ..........................................................................................178
		Engine and Fan Pump...............................................................................................183
		Pump Device, Drive Unit ..........................................................................................184
		Control Valve ....................................................................................................185
		Ride Control Valve ,Charging Block,Fan Motor .....................................................................186
		Steering Valve, EmergencySteering Pump (Optional).................................................................187
		Components in Control Valve.......................................................................................189
		Components in Steering Valve......................................................................................195
		Components in Charging Block......................................................................................199
		Components in Ride Control Valve..................................................................................205
		Front View of Transmission........................................................................................209
		Side View of Transmission.........................................................................................210
		Rear View of Transmission.........................................................................................211
		Cross-Sectional Drawing ofTorque Converter........................................................................212
		Cross-Sectional Drawing ofTransmission ...........................................................................213
		Cross-Sectional Drawing ofClutch Shaft............................................................................214
		Cross-Sectional Drawing ofTransmission Regulator Valve............................................................215
		Cross-Sectional Drawing ofTransmission Control Valve..............................................................216
	Group 5 Troubleshooting A.............................................................................................218
		Troubleshooting A Procedure.......................................................................................218
		MC Fault Code List................................................................................................219
		ECM1 & ECM2 Fault Code List.......................................................................................239
		ICF Fault Code List...............................................................................................263
		Satellite Terminal Fault Code List................................................................................265
		Monitor Unit Fault Code List......................................................................................267
		Controller Hardware FailureMC Fault Codes 11000 to 11002..........................................................268
		MC Fault Code 11003...............................................................................................269
		MC Fault Code 11004...............................................................................................270
		CAN Harness Check ................................................................................................271
		Engine FailureMC Fault Code 11103 ................................................................................292
		MC Fault Code 11105...............................................................................................293
		Pump FailureMC Fault Code 11204...................................................................................294
		MC Fault Code 11209...............................................................................................295
		Pilot FailureMC Fault Code 11312..................................................................................296
		MC Fault Code 11313...............................................................................................297
		Proportional Solenoid Valve FailureMC Fault Code 11412............................................................298
		MC Fault Code 11413...............................................................................................299
		MC Fault Code 11414, 11415, 11416,11417, 11418, 11419 ............................................................300
		Transmission FailureMC Fault Code 11600...........................................................................303
		MC Fault Code 11601...............................................................................................304
		MC Fault Code 11602...............................................................................................305
		MC Fault Code 11904...............................................................................................306
		MC Fault Code 11905...............................................................................................307
		CAN Data Reception FailureMC Fault Codes 11910, 11920.............................................................308
		CAN Harness Check(MC Fault Codes 11910, 11920)....................................................................309
		MC Fault Code 11914...............................................................................................312
		CAN Harness Check(MC Fault Code 11914)............................................................................313
		Other FailuresMC Fault Code 11901.................................................................................316
		Proportional Solenoid Valve TrubleCheck ..........................................................................317
		Each Connector Terminal Rolein ECM1...............................................................................320
		Each Connector Terminal Rolein ECM2...............................................................................323
		ICF, Satellite Terminal Fault Codes14000 to 14003.................................................................326
		ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106 ..................................................330
		Monitor Unit Fault Codes 13306,13308..............................................................................332
		Monitor Unit Fault Code 13312.....................................................................................333
		Monitor Unit Fault Code 13314.....................................................................................334
		Monitor Unit Fault Code 13334.....................................................................................335
	Group 6 Troubleshooting B.............................................................................................336
		Troubleshooting B Procedure.......................................................................................336
		Relationship between Machine TroubleSymptoms and Related Parts....................................................337
		Correlation between TroubleSymptoms and Part Failures ............................................................353
		Engine System Troubleshooting.....................................................................................367
		Front Attachment SystemTroubleshooting............................................................................376
		Travel System Troubleshooting ....................................................................................395
		Brake System Troubleshooting......................................................................................411
		Steering System Troubleshooting...................................................................................419
		Other System Troubleshooting......................................................................................422
		Exchange Inspection...............................................................................................444
		Bleeding Air from Brake (Axle)....................................................................................446
		One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ....447
	Group 7 Troubleshooting C.............................................................................................462
		Troubleshooting C (Trouble Shootingfor Monitor) Procedure.........................................................462
		Malfunction of Indicator Light CheckSystem........................................................................463
		Malfunction of Buzzer in Monitor..................................................................................465
		Malfunction of Coolant TemperatureGauge ..........................................................................467
		Malfunction of Transmission OilTemperature Gauge..................................................................469
		Malfunction of Fuel Gauge.........................................................................................471
		Malfunction of Turn Signal Indicators(Left and Right).............................................................473
		Malfunction of Hazard Light Indicator.............................................................................474
		Malfunction of High Beam Indicator................................................................................475
		Malfunction of Working Light Indicator............................................................................477
		Malfunction of Forward/ReverseSwitch Indicator ...................................................................479
		Malfunction of Maintenance Indicator..............................................................................481
		Malfunction of Preheat Indicator..................................................................................482
		Malfunction of Transmission OilTemperature........................................................................483
		Malfunction of Hydraulic OilTemperature Indicator.................................................................485
		Malfunction of Transmission WarningIndicator......................................................................487
		Malfunction of Air Filter RestrictionIndicator....................................................................489
		Malfunction of Engine Oil PressureIndicator.......................................................................491
		Malfunction of Overheat Indicator.................................................................................493
		Malfunction of Engine WarningIndicator............................................................................495
		Malfunction of Stop Indicator.....................................................................................496
		Malfunction of Service Indicator..................................................................................497
		Malfunction of Parking Brake Indicator............................................................................499
		Malfunction of Clearance LightIndicator...........................................................................501
		Malfunction of Brake Low Oil PressureIndicator....................................................................502
		Malfunction of Brake Low Oil LevelIndicator.......................................................................503
		Malfunction of Emergency SteeringIndicator (Optional) ............................................................505
		Malfunction of Low Steering OilPressure Indicator (Optional)......................................................507
		Malfunction of Discharge WarningIndicator.........................................................................509
		Malfunction of Monitor Display....................................................................................511
		Malfunction of Ride Control Indicator.............................................................................512
		Malfunction of Engine CoolantTemperature Display..................................................................513
	Group 8 Electrical System Inspection..................................................................................514
		Precautions for Inspection andMaintenance ........................................................................514
		Instructions for DisconnectingConnectors .........................................................................516
		Fuse Inspection...................................................................................................519
		Fusible Link Inspection...........................................................................................521
		Battery Voltage Check.............................................................................................522
		Alternator Check..................................................................................................523
		Continuity Check..................................................................................................525
		Voltage and Current Measurement...................................................................................527
		Check by False Signal.............................................................................................530

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.