Hitachi ZW330 6 Wheel Loader Troubleshooting Technical Manual – PDF DOWNLOAD

Description

Hitachi ZW330 6 Wheel Loader Troubleshooting Technical Manual

File Details:

Hitachi ZW330 6 Wheel Loader Troubleshooting Technical Manual

Language : English
Pages : 482
Size : 9.78 MB
Downloadable : Yes
Format : PDF
Part No : TTNGE40-EN-00

HITACHI ZW330 6 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL – PDF DOWNLOAD:

Image Preview:

Table of Contents:

Hitachi ZW330 6 Wheel Loader Troubleshooting Technical Manual

NGE40T-5-1
Group 1 Diagnosing Procedure
Introduction………………………………………………………………… T5-1-1
Diagnosis Procedure………………………………………………….. T5-1-2
Electric System Inspection………………………………………… T5-1-5
Precautions for Inspection and Maintenance………… T5-1-6
Instructions for Disconnecting Connectors…………… T5-1-8
Fuse Inspection………………………………………………………….T5-1-10
Fuse Box A……………………………………………………………..T5-1-11
Fuse Box B……………………………………………………………..T5-1-11
Fusible Link Inspection…………………………………………….T5-1-12
Battery Voltage Check………………………………………………T5-1-13
Alternator Check……………………………………………………….T5-1-14
Continuity Check………………………………………………………T5-1-16
Voltage and Current Measurement………………………..T5-1-18
24-Volt Circuit……………………………………………………….T5-1-18
5-Volt Circuit………………………………………………………….T5-1-24
Check by False Signal……………………………………………….T5-1-25
Test Harness……………………………………………………………….T5-1-26
Surge Voltage and Surge Suppression Diodes……..T5-1-28
Group 2 Monitor
Outline…………………………………………………………………………. T5-2-1
Operating Procedures of Service Menu………………….. T5-2-2
How to display service menu………………………………. T5-2-3
Engine Output Restriction Suspend……………………….. T5-2-4
Troubleshooting…………………………………………………………. T5-2-6
Monitoring………………………………………………………………….. T5-2-8
List of Monitoring Item………………………………………..T5-2-10
Controller Version……………………………………………………..T5-2-16
Issued Warning Record…………………………………………….T5-2-17
List of Alarm………………………………………………………….T5-2-18
Communication Terminal Status…………………………….T5-2-22
List of Communication Terminal Status……………T5-2-23
Machine Setting………………………………………………………..T5-2-24
Transmission Learning…………………………………………T5-2-26
Lift Arm Angle Sensor Learning…………………………T5-2-30
Digging Position Adjustment…………………………….T5-2-32
Aftertreatment Device No……………………………………….T5-2-34
Engine Tachometer…………………………………………………..T5-2-35
Transmission Oil Temperature Gauge and
DEF Level Gauge…………………………………………………..T5-2-36
Coolant Temperature Gauge…………………………………..T5-2-37
Group 3 e-Service
Outline…………………………………………………………………………. T5-3-1
List of Operation Data……………………………………………….. T5-3-2
List of Daily Report Data………………………………………. T5-3-2
List of Frequency Distribution Data……………………. T5-3-4
List of Total Operating Hours………………………………. T5-3-5
Snapshot Data…………………………………………………………….. T5-3-6
Communication System……………………………………………. T5-3-7
Group 4 Component Layout
Main Component……………………………………………………….. T5-4-1
Electric Component Layout (Overview)…………………. T5-4-4
Electrical System (Cab)………………………………………………. T5-4-5
Controller and Relays……………………………………………. T5-4-6
Right Console…………………………………………………………. T5-4-7
Monitor and Switches…………………………………………… T5-4-8
Monitor Panel………………………………………………………… T5-4-9
Electrical System (Relays)…………………………………………T5-4-10
Electrical System (Around Hydraulic Oil Tank)……..T5-4-11
Electrical System (Around Fuel Tank)……………………..T5-4-12
Engine…………………………………………………………………………T5-4-13
Aftertreatment Device……………………………………………..T5-4-14
Air Cleaner………………………………………………………………….T5-4-15
Hydraulic Pump ………………………………………………………..T5-4-16
Main Pump…………………………………………………………….T5-4-16
Pilot Pump……………………………………………………………..T5-4-16
Drive Unit……………………………………………………………………T5-4-17
Transmission and Torque Converter………………….T5-4-17
Multiple Control Valve………………………………………………T5-4-18
Brake Charge Valve/Combination Valve………………..T5-4-19
Flow Regulator Valve………………………………………………..T5-4-20
Brake Valve…………………………………………………………………T5-4-20
Ride Control Valve……………………………………………………..T5-4-20
Emergency Steering Group …………………………………….T5-4-21
Steering Valve…………………………………………………………….T5-4-21
Emergency Steering Pump …………………………………….T5-4-21
Joystick Steering System (Option)………………………….T5-4-22
Joystick Steering Valve………………………………………..T5-4-23
2-Spool Solenoid Valve Unit and
Pressure Sensor………………………………………………T5-4-23
Control Unit (JSS)………………………………………………….T5-4-24
Operator’s Seat (JSS)……………………………………………T5-4-25
DEF Tank and DEF Supply Module………………………….T5-4-26
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis
By Using Fault Codes) Procedure………………………… T5-5-1
MPDr. Fault Code Reference Table…………………………… T5-5-3
MC Fault Code List……………………………………………………… T5-5-9
Controller Hardware Failure………………………………… T5-5-9
SECTION 5
TROUBLESHOOTING
CONTENTS
TTNGE40-EN-00
NGE40T-5-2
CAN Data Reception Failure……………………………….T5-5-10
Engine Failure……………………………………………………….T5-5-11
Pump Failure…………………………………………………………T5-5-12
Pilot Failure……………………………………………………………T5-5-13
Proportional Solenoid Valve Failure………………….T5-5-16
Revolution Sensor Failure……………………………………T5-5-23
Learning Failure……………………………………………………T5-5-24
Switch Failure………………………………………………………..T5-5-24
Temperature Sensor Failures………………………………T5-5-25
Other Sensor Failures…………………………………………..T5-5-26
Alarms on Monitor……………………………………………….T5-5-27
Monitor Controller (Monitor) Fault Code List……….T5-5-29
Monitor Controller (Information) Fault Code List…T5-5-31
Column Display Controller Fault Code List……………T5-5-34
Air Conditioner Controller Fault Code List…………….T5-5-36
Communication Terminal Fault Code List……………..T5-5-37
JCU Fault Code List……………………………………………………T5-5-38
ECM Fault Code List…………………………………………………..T5-5-43
MC Fault Codes 111000 to 111002…………………………………………………T5-5-63
111003……………………………………………………………………T5-5-64
111006, 111007, 111009……………………………………..T5-5-66
111008, 111010, 111014, 111025………………………T5-5-70
111103, 111105, 111106……………………………………..T5-5-75
111205, 111207…………………………………………………….T5-5-76
111200, 111202, 111203……………………………………..T5-5-77
111217, 111312…………………………………………………….T5-5-78
111204……………………………………………………………………T5-5-79
111206, 111208…………………………………………………….T5-5-80
111311, 111313…………………………………………………….T5-5-81
111407……………………………………………………………………T5-5-82
111410……………………………………………………………………T5-5-83
111411……………………………………………………………………T5-5-84
111412……………………………………………………………………T5-5-85
111413……………………………………………………………………T5-5-86
111414 to 111419, 111421………………………………….T5-5-87
111422……………………………………………………………………T5-5-88
111423……………………………………………………………………T5-5-89
111600 to 111602…………………………………………………T5-5-90
111900……………………………………………………………………T5-5-91
111901……………………………………………………………………T5-5-92
111902……………………………………………………………………T5-5-93
111700 to 111705…………………………………………………T5-5-94
120000 to 120005……………………………………………….. T5-5-96 120008, 120014, 120015……………………………………. T5-5-96
Column Display Controller Fault Code 115001…….T5-5-97
Monitor Controller (Monitor) Fault Codes 120300………………………………………………………………….. T5-5-98
Monitor Controller (Information) Fault Codes 114010, 114011, 114013……………………………………..T5-5-66
114012, 114014, 114015……………………………………..T5-5-70
120400, 120401…………………………………………………….T5-5-99
113311………………………………………………………………… T5-5-100
Column Display Controller (Information) Fault Codes
120500 to 120504……………………………………………… T5-5-102
120505 to 120507, 120517………………………………. T5-5-103
JCU Fault Codes 116003, 116004…………………………………………………. T5-5-104
116006, 116007, 116008………………………………….. T5-5-105
116118………………………………………………………………… T5-5-106
116119………………………………………………………………… T5-5-107
Air Conditioner Controller Fault Codes 11 to 22……………………………………………………………… T5-5-108 43 to 92……………………………………………………………… T5-5-108
CAN1 Harness Check………………………………………………..T5-5-64
CAN2 Harness Check………………………………………………..T5-5-72
CAN3 Harness Check…………………………………………….. T5-5-109
Specification of Transmission Oil Temperature
Sensor…………………………………………………………………….T5-5-91
Specification of Hydraulic Oil Temperature
Sensor…………………………………………………………………….T5-5-92
Specification of Axle Oil Temperature Sensor………T5-5-93
Fuel Level Sensor Specifications………………………….. T5-5-101
Hydraulic Oil Level Switch……………………………………. T5-5-102
Brake Oil Pressure Switch……………………………………… T5-5-103
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using
Troubleshooting Symptom) Procedure……………… T5-6-1
Relationship between Machine Trouble Symptom
and Related Parts…………………………………………………… T5-6-3
Correlation between Trouble Symptom and
Part Failures……………………………………………………….T5-6-25
Engine System………………………………………………………T5-6-26
All Actuator System……………………………………………..T5-6-28
Front Attachment System…………………………………..T5-6-31
Steering System……………………………………………………T5-6-35
Travel System………………………………………………………..T5-6-37
Brake System…………………………………………………………T5-6-40
Other System………………………………………………………..T5-6-41
Engine System Troubleshooting…………………………….T5-6-45
All Actuator System Troubleshooting…………………….T5-6-51
Front Attachment System Troubleshooting………….T5-6-57
Steering System Troubleshooting………………………….T5-6-67
Travel System Troubleshooting………………………………T5-6-72
Brake System Troubleshooting……………………………….T5-6-80
Other System Troubleshooting……………………………….T5-6-85
Exchange Inspection………………………………………………..T5-6-99
Air Bleeding Procedures for Brake (Axle)……………. T5-6-101
Group 7 Air Conditioner
Outline………………………………………………………………………… T5-7-1 Component Layout……………………………………………….. T5-7-2
Functions of Main Parts……………………………………………. T5-7-4
Troubleshooting………………………………………………………… T5-7-9
Air Conditioner Controller Fault Code List…………… T5-7-10
Air Conditioner Controller Fault Codes 11 to 22………………………………………………………………….T5-7-11
43 to 92………………………………………………………………… T5-7-12
Faulty cooling…………………………………………………………….T5-7-14
Faulty heating……………………………………………………………T5-7-24
Faulty air vent switch………………………………………………..T5-7-27
Faulty fresh/re-circulated air selection………………….T5-7-27
TTNGE40-EN-00
NGE40T-5-3
Ambient temperature higher or lower………………….T5-7-27
Noise……………………………………………………………………………T5-7-28
Blower motor does not operate……………………………..T5-7-30
Compressor clutch does not operate…………………….T5-7-31
Cooling circuit check by using manifold gauge…..T5-7-32
Work after Replacing Components………………………. T5-7-34
Refill Compressor Oil………………………………………………. T5-7-35
Charge Air Conditioner

Description:

Hitachi ZW330 6 Wheel Loader Troubleshooting Technical Manual

INTRODUCTION:

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.

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]