Technical Manual Hitachi ZW100, ZW120 Wheel Loader | TT4FJ-E-00

Technical Manual Hitachi ZW100, ZW120 Wheel Loader TT4FJ-E-00 (Preview)

TT4FJ-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 Operational Performance Standard Table
— ZW120 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 Operationg 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
— Sattellite Communication System
– Group 4 Component Lay out
— Main Component Layout (Upperstructure)
— Main Component Layout (Travel System)
— Electrical System (Overview)
— Electrical System (Relay and Others)
— Electrical System (In Cab)
— Electrical System (Relays)
— Front Console
— 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 11103
— 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, 102, 108, 110, 157
— ECM Fault Codes 168, 172, 174, 190, 628, 633
— ECM Fault Codes 636, 651 to 654, 723, 1077, 1079, 1080
— ECM Fault Codes 1239, 1347, 1485, 10003, 10004
— ECM Fault Codes 10005, 10007, 10015 to 10026
— ECM Fault Codes 10027, 10028
— 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 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
SA.pdf
– SA01 to 10 _ZW220 to 310_ E.pdf
– SA11 to 20 _ZW220 to 310_ E.pdf
– SA21 to 30 _ZW220 to 310_ E.pdf