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Troubleshooting Manual for Hitachi ZW310 Wheel Loader (TT4HA-E-00) PDF
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- Hitachi ZW310 Wheel Loader Troubleshooting Technical Manual
- Part No:TT4HA-E-00
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Description
Hitachi ZW310 Wheel Loader Troubleshooting Technical Manual (TT4HA-E-00)
FILE DETAILS:
Hitachi ZW310 Wheel Loader Troubleshooting Technical Manual (TT4HA-E-00)
- Manual Language:English
- Downloadable:Yes
- Pages: 569
- Size: 5.26 MB
- Format:PDF
HITACHI ZW310 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TT4HA-E-00) – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Hitachi ZW310 Wheel Loader Troubleshooting Technical Manual (TT4HA-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 ZW310 Wheel Loader Troubleshooting Technical Manual (TT4HA-E-00)
ZW310_TT4HA-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 INVOLVING MULTIPLE 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 CONTAINING FLAMMABLE 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 GROUP CONTENTS................................................................................................ 34 SECTION 4 OPERATIONALPERFORMANCE TEST..................................................................................... 36 Group 1 Introduction.................................................................................................. 38 Operational Performance Tests..................................................................................... 38 Preparation for Performance Tests................................................................................. 39 Group 2 Standard...................................................................................................... 40 Operational Performance Standard Table............................................................................ 40 Main Pump P-Q Curve............................................................................................... 50 Sensor Activating Range........................................................................................... 52 Group 3 Engine Test................................................................................................... 54 Engine Speed...................................................................................................... 54 Engine Compression Pressure ...................................................................................... 57 Valve Clearance................................................................................................... 59 Lubricant Consumption ............................................................................................ 61 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 Stopper and Bell CrankClearances .......................................................................... 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 Pressure.............................................................................................. 83 Steering Relief Pressure.......................................................................................... 85 Overload Relief Valve Set Pressure................................................................................ 87 Main Pump Flow Rate............................................................................................... 89 Regulator Adjustment.............................................................................................. 93 Service Brake Pressure (Front and Rear)........................................................................... 95 Parking Brake Pressure............................................................................................ 97 Brake Accumulated Pressure........................................................................................ 99 Brake Warning Set Pressure (Decrease).............................................................................101 Brake Warning Set Pressure (Increase).............................................................................103 Transmission Clutch Pressure......................................................................................105 Torque Converter Pressure(Inlet and Outlet).......................................................................106 Group 6 Adjustment....................................................................................................108 Transmission Learning.............................................................................................108 Lift Arm Angle SensorLearning (Optional)..........................................................................113 Unit Injector Setting.............................................................................................115 SECTION 5 TROUBLESHOOTING.................................................................................................120 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)...............................................................................160 ICF Controller ...................................................................................................162 ICF Various Setup (ICF Controller)................................................................................163 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 Group 3 e-Wheel.......................................................................................................182 Outline...........................................................................................................182 List of Daily Report Data.........................................................................................183 List of Frequency Distribution Data...............................................................................184 List of Total Operationg Hours....................................................................................185 List of Alarm.....................................................................................................186 List of failure...................................................................................................187 How to Download and Upload Data ofICF.............................................................................188 Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX............................................191 List of ICF Fault Code............................................................................................203 List of Fault Code of SattelliteCommunication Terminal............................................................204 Group 4 Component Layout..............................................................................................208 Main Component Layout (Overview)..................................................................................208 Main Component Layout (Upper-structure) ..........................................................................209 Main Component Layout (TravelSystem)..............................................................................210 Electric Component Layout (Overview)..............................................................................211 Electrical System (Cab) ..........................................................................................212 Engine and Fan Pump...............................................................................................217 Pump Device, Drive Unit ..........................................................................................218 Control Valve ....................................................................................................219 Ride Control Valve ,Charging Block,Fan Motor .....................................................................220 Steering Valve, EmergencySteering Pump (Optional).................................................................221 Components in Control Valve.......................................................................................223 Components in Steering Valve......................................................................................229 Components in Charging Block......................................................................................233 Components in Ride Control Valve..................................................................................239 Front View of Transmission........................................................................................243 Side View of Transmission.........................................................................................244 Rear View of Transmission.........................................................................................245 Cross-Sectional Drawing ofTorque Converter........................................................................246 Cross-Sectional Drawing ofTransmission ...........................................................................247 Cross-Sectional Drawing ofClutch Shaft............................................................................248 Cross-Sectional Drawing ofTransmission Regulator Valve............................................................249 Cross-Sectional Drawing ofTransmission Control Valve..............................................................250 Group 5 Troubleshooting A.............................................................................................252 Troubleshooting A Procedure.......................................................................................252 MC Fault Code List................................................................................................253 ECM1 & ECM2 Fault Code List.......................................................................................273 ICF Fault Code List...............................................................................................297 Satellite Terminal Fault Code List................................................................................299 Monitor Unit Fault Code List......................................................................................301 Controller Hardware FailureMC Fault Codes 11000 to 11002..........................................................302 MC Fault Code 11003...............................................................................................303 MC Fault Code 11004...............................................................................................304 CAN Harness Check ................................................................................................305 Engine FailureMC Fault Code 11103 ................................................................................326 MC Fault Code 11105...............................................................................................327 Pump FailureMC Fault Code 11204...................................................................................328 MC Fault Code 11209...............................................................................................329 Pilot FailureMC Fault Code 11312..................................................................................330 MC Fault Code 11313...............................................................................................331 Proportional Solenoid Valve FailureMC Fault Code 11412............................................................332 MC Fault Code 11413...............................................................................................333 MC Fault Code 11414, 11415, 11416,11417, 11418, 11419 ............................................................334 Transmission FailureMC Fault Code 11600...........................................................................337 MC Fault Code 11601...............................................................................................338 MC Fault Code 11602...............................................................................................339 MC Fault Code 11904...............................................................................................340 MC Fault Code 11905...............................................................................................341 CAN Data Reception FailureMC Fault Codes 11910, 11920.............................................................342 CAN Harness Check(MC Fault Codes 11910, 11920)....................................................................343 MC Fault Code 11914...............................................................................................346 CAN Harness Check(MC Fault Code 11914)............................................................................347 Other FailuresMC Fault Code 11901.................................................................................350 Proportional Solenoid Valve TrubleCheck ..........................................................................351 Each Connector Terminal Rolein ECM1...............................................................................354 Each Connector Terminal Rolein ECM2...............................................................................357 ICF, Satellite Terminal Fault Codes14000 to 14003.................................................................360 ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106 ..................................................364 Monitor Unit Fault Codes 13306,13308..............................................................................366 Monitor Unit Fault Code 13312.....................................................................................367 Monitor Unit Fault Code 13314.....................................................................................368 Monitor Unit Fault Code 13334.....................................................................................369 Group 6 Troubleshooting B.............................................................................................370 Troubleshooting B Procedure.......................................................................................370 Relationship between Machine TroubleSymptoms and Related Parts....................................................371 Correlation between TroubleSymptoms and Part Failures ............................................................387 Engine System Troubleshooting.....................................................................................401 Front Attachment SystemTroubleshooting............................................................................410 Travel System Troubleshooting ....................................................................................429 Brake System Troubleshooting......................................................................................445 Steering System Troubleshooting...................................................................................453 Other System Troubleshooting......................................................................................456 Exchange Inspection...............................................................................................478 Bleeding Air from Brake (Axle)....................................................................................480 One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ....481 Group 7 Troubleshooting C.............................................................................................496 Troubleshooting C (Trouble Shootingfor Monitor) Procedure.........................................................496 Malfunction of Indicator Light CheckSystem........................................................................497 Malfunction of Buzzer in Monitor..................................................................................499 Malfunction of Coolant TemperatureGauge ..........................................................................501 Malfunction of Transmission OilTemperature Gauge..................................................................503 Malfunction of Fuel Gauge.........................................................................................505 Malfunction of Turn Signal Indicators(Left and Right).............................................................507 Malfunction of Hazard Light Indicator.............................................................................508 Malfunction of High Beam Indicator................................................................................509 Malfunction of Working Light Indicator............................................................................511 Malfunction of Forward/ReverseSwitch Indicator ...................................................................513 Malfunction of Maintenance Indicator..............................................................................515 Malfunction of Preheat Indicator..................................................................................516 Malfunction of Transmission OilTemperature........................................................................517 Malfunction of Hydraulic OilTemperature Indicator.................................................................519 Malfunction of Transmission WarningIndicator......................................................................521 Malfunction of Air Filter RestrictionIndicator....................................................................523 Malfunction of Engine Oil PressureIndicator.......................................................................525 Malfunction of Overheat Indicator.................................................................................527 Malfunction of Engine WarningIndicator............................................................................529 Malfunction of Stop Indicator.....................................................................................530 Malfunction of Service Indicator..................................................................................531 Malfunction of Parking Brake Indicator............................................................................533 Malfunction of Clearance LightIndicator...........................................................................535 Malfunction of Brake Low Oil PressureIndicator....................................................................536 Malfunction of Brake Low Oil LevelIndicator.......................................................................537 Malfunction of Emergency SteeringIndicator (Optional) ............................................................539 Malfunction of Low Steering OilPressure Indicator (Optional)......................................................541 Malfunction of Discharge WarningIndicator.........................................................................543 Malfunction of Monitor Display....................................................................................545 Malfunction of Ride Control Indicator.............................................................................546 Malfunction of Engine CoolantTemperature Display..................................................................547 Group 8 Electrical System Inspection..................................................................................548 Precautions for Inspection andMaintenance ........................................................................548 Instructions for DisconnectingConnectors .........................................................................550 Fuse Inspection...................................................................................................553 Fusible Link Inspection...........................................................................................555 Battery Voltage Check.............................................................................................556 Alternator Check..................................................................................................557 Continuity Check..................................................................................................559 Voltage and Current Measurement...................................................................................561 Check by False Signal.............................................................................................564 SERVICE MANUAL REVISION REQUEST FORM......................................................................................568 THE ATTACHED DIAGRAM LIST.................................................................................................569
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.
