Technical Manual Hitachi ZW100-G, ZW120-G Wheel Loader | TT4FK-E-00

Technical Manual Hitachi ZW100-G, ZW120-G Wheel Loader TT4FK-E-00 (Preview)

TT4FL-E-00
INTRODUCTION
SAFETY
SECTION AND GROUP CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
ZW100-G Operational Performance Standard Table
ZW120-G Operational Performance Standard Table
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Engine Compression Pressure
Valve Clearance
Group 4 Wheel Loader Test
Travel Speed
Service Brake Capacity
Parking Brake Capacity
Hydraulic Cylinder Cycle Time
Dig Function Drift
Control Lever Operating Force
Control Lever and Pedal Stroke
Group 5 Component Test
Main Pump Delivery Pressure
HST Pump Delivery Pressure (HST Pump Relief Pressure)
HST Charge Pump Delivery Pressure
Transmission Charge Pump Delivery Pressure
Main Relief Valve Pressure
HST Charge Relief Pressure
Overload Relief Pressure
Steering Relief Pressure
HST Pump Displacement angle Control Pressure
HST Motor Displacement angle Control Pressure
Transmission Clutch Pressure
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosing Procedure
How to Operate Service Mode of Monitor Panel
Display List of Monitor Service Mode
Group 2 Dr.ZX
Outline
Operation
Self-Diagnostic Result
Select Controller
Main Controller
Main Menu Monitor Display
Setting
Recorded Data Display
Password Change
Engine Controller
Main Menu Monitor Display
Recorded Data Display
Password Change
ICF Controller
Information C/U Various Setup
Save Data Check
Password Change
Monitor Unit
Monitoring
Various Settings
Internal Hour Meter Synchronization
Password Change
Group 3 e-Wheel
Outline
List of Daily Report Data
List of Frequency Distribution Data
List of Total Operating Hours
List of Alarm
How to Download and Upload Data of ICF
Various Setup of ICF and Satellite Communication Terminal by Using Dr.ZX
List of Fault Code
Satellite Communication System
Group 4 Component Layout
Main Component Layout (Upperstructure)
Main Component Layout (Travel System)
Electrical System (Overview)
Electrical System (Relay and Others)
Electrical System (In Canopy)
Electrical System (In Cab)
Electrical System (Relays)
Front Console (In Canopy)
Front Console (In Cab)
Monitor Panel
Engine
Pump Device
Transmission
Control Valve/Priority Valve
Group 5 Troubleshooting A
Troubleshooting A Procedure
Fault Code List
Controller Hardware Failure MC Fault Code 11004
CAN Harness Check
MC Fault Code 11330
MC Fault Code 11331
MC Fault Code 11332
MC Fault Code 11430
MC Fault Code 11433
MC Fault Code 11450
MC Fault Code 11451
MC Fault Code 11452
MC Fault Code 11455
MC Fault Code 11456
MC Fault Code 11622
MC Fault Code 11904
MC Fault Code 11801
Can Data Reception Failure MC Fault Codes 11910
Can Harness Check Fault Code 11910
MC Fault Code 11914
Can Harness Check Fault Code 11914
ECM Fault Codes 100, 110, 168, 190, 628, 1077, 1485, 10007, 10018, 10024
ECM Fault Codes 10027 to 10034
ICF, Satellite Terminal Fault Codes 14000 to 14003
ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14107
Monitor Unit Fault Code 13304
Monitor Unit Fault Codes 13306, 13308
Monitor Unit Fault Code 13310
Monitor Unit Fault Code 13311
Monitor Unit Fault Code 13315
Monitor Unit Fault Code 13319
Fault Detection of Proportional Solenoid Valve
Group 6 Troubleshooting B
Troubleshooting B Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
Front Attachment System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Steering System Troubleshooting
Other System Troubleshooting
Releasing Parking Brake in Case of Emergency and when Engine Stops
Recovery of Released Parking Brake
One Part of Data, “Daily Report Data”, “Distribution Data”, “Total Operating Hours” and “Alarm” is Not Recorded
Group 7 Troubleshooting C
Troubleshooting C (Trouble Shooting for Monitor Panel) Procedure
Malfunction of Indicator Light Check System
Malfunction of Buzzer in Monitor Panel
Malfunction of Coolant Temperature Gauge
Malfunction of HST Oil Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Turn Signal Indicators (Left and Right)
Malfunction of Hazard Light Indicator
Malfunction of High Beam Indicator
Malfunction of Working Light Indicator
Malfunction of Maintenance Indicator
Malfunction of Preheat Indicator
Malfunction of HST Oil Temperature Indicator
Malfunction of HST Warning Indicator
Malfunction of Engine Oil Pressure Indicator
Faulty Overheat Indicator
Malfunction of Engine Warning Indicator
Malfunction of Stop Indicator
Malfunction of Service Indicator
Malfunction of Parking Brake Indicator
Malfunction of Clearance Light Indicator
Malfunction of Brake Low Oil Level Indicator
Malfunction of Emergency Steering Indicator (Optional)
Malfunction of Low Steering Oil Pressure Indicator (Optional)
Malfunction of Discharge Warning Indicator
Malfunction of Monitor Display
Malfunction of Ride Control Indicator (Optional)
Malfunction of Engine Coolant Temperature Display
Group 8 Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link and Fuse (100A) Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST