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Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual (TT92C1-E-01) – PDF Download
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- Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual
- Part No:TT92C1-E-01
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Description
Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual (TT92C1-E-01)
File Details:
Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual (TT92C1-E-01)
- Manual Language:English
- Downloadable:Yes
- Pages: 155
- Size: 4.27 MB
- Format:PDF
HITACHI ZW330 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TT92C1-E-01) – PDF DOWNLOAD:
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Description:
Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual (TT92C1-E-01)
- To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operation and Maintenance Manual.
- To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
- For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
- The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service.
- This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
Table Of Contents:
Hitachi ZW330 Wheel Loader Troubleshooting Technical Manual (TT92C1-E-01)
TT92C1-E-01........................................................................................................................................... 1 Foreword.............................................................................................................................................. 3 Safety Precautions.................................................................................................................................... 4 Safety Symbols........................................................................................................................................ 5 Symbols............................................................................................................................................... 6 CONTENTS.............................................................................................................................................. 7 01 Troubleshooting.................................................................................................................................... 9 Cautions Regarding Troubleshooting................................................................................................................ 11 How to Use Quick Troubleshooting Table............................................................................................................ 12 Safety Precautions................................................................................................................................ 13 Torque Converter and Transmission Group........................................................................................................... 14 1. Machine dose not move in any shift lever position.......................................................................................... 14 2. Machine dose not move at a certain shift lever position. (OR:Machine moves only in a certain shift lever position.)........................ 15 3. Machine moves at the neutral position. (Example: Machine moves forward at the neutral position.)........................................... 16 4. Large shock at starting or changing speed / direction...................................................................................... 17 5. Large time lag at starting or changing speed / direction................................................................................... 18 6. Low power of traction / pushing (Defective torque converter or transmission)............................................................... 19 7. Torque converter oil is overheating........................................................................................................ 20 8. Machine moves reverse when starting to climb up on a slope using inching brake............................................................. 21 9. Automatic speed change is not possible..................................................................................................... 22 10. Downshift button does not work............................................................................................................ 23 Hydraulic Group................................................................................................................................... 24 1. Boom and/or bucket do not move............................................................................................................. 24 2. Boom and/or bucket have low power, or move too slowly...................................................................................... 25 3. Excessive cylinder drift................................................................................................................... 26 4. Boom and/or bucket are spongy. (Holding bucket against the ground is not possible-front wheels off the ground.)............................ 27 5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work............................................................ 28 6. Steering is not possible or hard to steer.................................................................................................. 29 7. Machine sways, or has a shock during steering.............................................................................................. 30 8. ELS (Efficient Loading System) does not work. (Excavating and scooping tractive power does not become up during ELS working condition.).... 31 9. Ride control does not work................................................................................................................. 32 10. Fan motor rotates abnormally or does not rotate........................................................................................... 33 11. Abnormal noise in hydraulic system........................................................................................................ 34 12. Others.................................................................................................................................... 35 Brake Group....................................................................................................................................... 36 1. Brake does not work well. (In the worst case, the brake does not work at all.)............................................................. 36 2. Brake is dragging when released............................................................................................................ 37 3. Stepping on the brake pedal sounds the buzzer.............................................................................................. 38 4. Accumulator pressure does not rise, or too slow in rising.................................................................................. 39 5. Parking brake does not work. (or: Releasing the parking brake is not possible.)............................................................ 40 Electrical Group.................................................................................................................................. 41 1. Instrument panel does not indicate properly................................................................................................ 41 2. Fuse for controller is blown............................................................................................................... 42 Error code (for chassis)...................................................................................................................... 43 Error code (for engine)....................................................................................................................... 46 Operator Station Group............................................................................................................................ 53 Air conditioner............................................................................................................................... 53 03 Measurement for Performance Check.................................................................................................................. 61 Cautions on Safety................................................................................................................................ 62 Standard Measurement Values for Performance Check................................................................................................. 63 Preparation for Performance Check................................................................................................................. 66 Engine............................................................................................................................................ 68 Measuring engine speed........................................................................................................................ 68 Measurement instrument.................................................................................................................... 68 Standard measurement value (Normal mode).................................................................................................. 68 Clutch Oil Pressure............................................................................................................................... 72 Measuring clutch oil pressure................................................................................................................. 72 Hydraulic Cylinder................................................................................................................................ 73 Cylinder natural drift........................................................................................................................ 73 Measurement instrument.................................................................................................................... 73 Standard measurement value (mm/min) (in/min).............................................................................................. 73 Measurement procedure..................................................................................................................... 73 Boom Rising Time.................................................................................................................................. 74 Measurement instrument........................................................................................................................ 74 Warm-up the engine before measuring boom rising time.......................................................................................... 74 Standard measurement value (sec).............................................................................................................. 74 Measurement procedure......................................................................................................................... 74 Full Steering Cycle Time.......................................................................................................................... 76 Measurement instrument........................................................................................................................ 76 Warm-up the engine before measuring full steering time........................................................................................ 76 Standard measurement value (sec).............................................................................................................. 76 Measurement procedure......................................................................................................................... 76 Loading/Steering Circuit Relief Valve............................................................................................................. 78 Loading circuit relief valve setting pressures................................................................................................ 78 Measurement instruments................................................................................................................... 78 Gauge port................................................................................................................................ 78 Standard measurement value MPa (kgf/cm2) (psi)............................................................................................ 79 Measuring loading circuit main relief pressure............................................................................................ 79 Measuring loading circuit overload relief pressure........................................................................................ 81 Measuring pilot circuit relief pressure................................................................................................... 82 Steering circuit relief valve setting pressures............................................................................................... 83 Measurement instruments................................................................................................................... 83 Gauge port................................................................................................................................ 83 Standard measurement value MPa (kgf/cm2) (psi)............................................................................................ 84 Measuring steering circuit main relief pressure........................................................................................... 84 Measuring steering circuit overload relief pressure....................................................................................... 86 Measuring pilot circuit relief pressure (reducing pressure)............................................................................... 87 Service Brake..................................................................................................................................... 89 Service brake performance check............................................................................................................... 89 Condition................................................................................................................................. 89 Standard measurement value................................................................................................................ 89 Parking Brake..................................................................................................................................... 90 Parking brake performance check............................................................................................................... 90 Condition................................................................................................................................. 90 Standard measurement value................................................................................................................ 90 Brake Circuit Oil Pressure........................................................................................................................ 91 Unloader valve setting pressure............................................................................................................... 91 Measurement instrument.................................................................................................................... 92 Gauge port................................................................................................................................ 92 Standard measurement value................................................................................................................ 92 Measurement procedure..................................................................................................................... 92 Brake valve oil pressure...................................................................................................................... 94 Measurement instrument.................................................................................................................... 94 Gauge port................................................................................................................................ 94 Measurement procedure..................................................................................................................... 94 Brake valve performance................................................................................................................... 95 Accumulator Circuit Charging Time................................................................................................................. 96 Measurement instrument........................................................................................................................ 96 Gauge installation position................................................................................................................... 96 Standard measurement valve (sec).............................................................................................................. 97 Measurement procedure......................................................................................................................... 97 Number of Brake Pedal Applications................................................................................................................ 98 Standard measurement value.................................................................................................................... 98 Measurement procedure......................................................................................................................... 98 Possible causes of extremely low measurement value and solution............................................................................... 98 Declutch Engagement............................................................................................................................... 99 Measurement instrument........................................................................................................................ 99 Warm-up the engine before measuring declutch engagement....................................................................................... 99 Standard measurement value.................................................................................................................... 99 Cause of extremely high measurement value and solution........................................................................................ 99 Measurement procedure......................................................................................................................... 99 MEMO..............................................................................................................................................100 Check & Adjustment....................................................................................................................................101 13 Check & Adjustment Chassis Group...............................................................................................................103 Linkage Pin...................................................................................................................................104 Liner.....................................................................................................................................104 Adjustment............................................................................................................................105 Bucket hinge pin section..............................................................................................................106 How to assemble.......................................................................................................................106 Center Pin....................................................................................................................................107 Adjusting shim............................................................................................................................107 Installing bearing cover..................................................................................................................107 Installing bearing outer ring.............................................................................................................108 23 Check & Adjustment Power Group.................................................................................................................109 Engine........................................................................................................................................110 Measuring engine speed....................................................................................................................110 Measurement instrument................................................................................................................110 Standard measurement value............................................................................................................110 Measuring engine oil pressure.............................................................................................................110 Measurement instrument................................................................................................................110 Install position......................................................................................................................110 Standard measurement value............................................................................................................110 Propeller Shaft...............................................................................................................................111 Propeller shaft phase.....................................................................................................................111 Second propeller shaft alignment..........................................................................................................111 Tightening torque.........................................................................................................................112 Axle..........................................................................................................................................113 Axle nut tightening procedure.............................................................................................................113 Differential gear adjustment procedure....................................................................................................114 Preload adjustment....................................................................................................................114 Bearing installation..................................................................................................................115 Oil seal installation.................................................................................................................115 Adjusting tooth contact...............................................................................................................116 MEMO..........................................................................................................................................118 33 Check & Adjustment Torque Converter and Transmission Group.....................................................................................119 Clutch Oil Pressure...........................................................................................................................120 Measuring clutch oil pressure.............................................................................................................120 43 Check & Adjustment Hydraulic Group.............................................................................................................121 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)...............................................................122 Loading circuit relief valve setting pressures............................................................................................122 Measurement instruments...............................................................................................................122 Gauge port............................................................................................................................122 Standard measurement value MPa (kgf/cm2) (psi)........................................................................................123 Measuring loading circuit main relief pressure........................................................................................123 Measuring loading circuit overload relief pressure....................................................................................125 Measuring pilot circuit relief pressure...............................................................................................126 Ride control circuit reducing valve setting pressures (OPT)...............................................................................127 Measurement instruments...............................................................................................................127 Gauge port............................................................................................................................127 Standard measurement value MPa (kgf/cm2) (psi)........................................................................................128 Measuring ride control circuit reducing pressure......................................................................................128 Steering circuit relief valve setting pressures...........................................................................................130 Measurement instruments...............................................................................................................130 Gauge port............................................................................................................................130 Standard measurement value MPa (kgf/cm2) (psi)........................................................................................131 Measuring steering circuit main relief pressure.......................................................................................131 Measuring steering circuit overload relief pressure...................................................................................133 Measuring pilot circuit relief pressure (reducing pressure)...........................................................................134 Hydraulic Cylinder............................................................................................................................135 Cylinder natural drift....................................................................................................................135 Measurement instrument................................................................................................................135 Standard measurement value (mm/min) (in/min)..........................................................................................135 Measurement procedure.................................................................................................................135 Stop Valve....................................................................................................................................137 Stop valve adjustment procedure...........................................................................................................137 MEMO..........................................................................................................................................138 53 Check & Adjustment Brake Group.................................................................................................................139 Brake Circuit Oil Pressure....................................................................................................................140 Unloader valve setting pressure...........................................................................................................140 Measurement instrument................................................................................................................141 Gauge port............................................................................................................................141 Standard measurement value............................................................................................................141 Measurement procedure.................................................................................................................141 Brake valve oil pressure..................................................................................................................142 Measurement instrument................................................................................................................142 Gauge port............................................................................................................................142 Measurement procedure.................................................................................................................142 Brake valve performance...............................................................................................................143 Service Brake.................................................................................................................................144 Service brake performance check...........................................................................................................144 Condition.............................................................................................................................144 Standard measurement value............................................................................................................144 Service brake friction plate wear measurement.............................................................................................145 Measurement procedure.................................................................................................................146 Cautions on installing brake discs........................................................................................................146 Parking Brake.................................................................................................................................147 Parking brake performance check...........................................................................................................147 Condition.............................................................................................................................147 Standard measurement value............................................................................................................147 Maintenance Log.......................................................................................................................................148 Notes.................................................................................................................................................152
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]
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